Looking for a solution, Tai consulted long-time supplier, Expand Machinery, a family-owned business in Chatsworth, CA, that builds machine tool systems.

Tai had been working with Expand Machinery for several years, using a wide range of Expand milling machines, most of which use controls from Mitsubishi Electric Automation.

Over the years, Tai has slowly replaced all other machine brands with Expand and Mitsubishi Electric products. “Both companies give me what I need: super support, performance and reliability,” he says.

After working closely with Tai, Expand’s general manager, Ravjeet Singh, suggested automating the process of loading and unloading machines using Mitsubishi’s LoadMate Plus system.

Expand Machinery developed and integrated a 4-foot-by-4-foot machine-tending cell equipped with a Mitsubishi RV20 six-axis robot. Photo courtesy Mitsubishi Electric Automation Inc.

LoadMate Plus is a standardized robotic system for machine tending. Expand developed and integrated a 4-foot-by-4-foot cell with a Mitsubishi RV20 six-axis robot. The cell easily connected to one of Tai’s machine tools, the GenMill 5X-12. Because this five-axis milling system was already equipped with a Mitsubishi CNC, getting everything to communicate was easy.

“The LoadMate Plus has been specifically created for easy setup and use,” says Mitsubishi Electric account manager David Contreras.

Plug-and-Play Machine Tending

The LoadMate Plus is a compact, portable robotic cell capable of handling payloads up to 20 kilograms with reaches up to 1,388 millimeters. A safe, self-contained cell, the LoadMate Plus can be equipped with a variety of Mitsubishi six-axis robots, including the RV7, RV-8, RV-13 and RV-20 series.

The cell was designed for plug-and-play operation. An Ethernet connection is all that’s required to integrate the cell with Mitsubishi’s M8 Series CNC. 

In addition, the system offers easy programming of the robot thanks to direct robot control with CNC software. That means Tai can program and adjust on the fly using menus and G-code from the same screen used for the machine tool. There’s no need for robot programming experience or a teach pendant.

The cell can be used for more than just tending machine tools. It can also be deployed in pick-and-place, inspection, assembly and packing applications.

With the LoadMate Plus, TL Aerotek’s milling machine can run unattended for 24 hours, tripling normal output. Photo courtesy Mitsubishi Electric Automation Inc.

To ensure precise placement of the part to be milled, the robot works with a flexible quick-change pallet system from Schunk. “Working with Tai, we chose to focus on a pallet system that allows the robot to pick up parts from the same location each time, so you don’t have to reprogram the robot from part to part,” says Singh. “We chose Schunk for our pallet system because of its rigidity, accuracy and durability.”

It only takes 15 minutes to place 10 blanks on the loading shelves. From there, the system automatically loads and unloads the machine. That means Tai no longer has to stand by to remove a finished part and load new material. The LoadMate Plus does it all and will keep doing it until the loading shelf is empty. In fact, after implementation at TL Aerotek, the system ran unattended for 24 hours, tripling normal output. Tai is now able to complete a month’s quota in just a week.

“I like to be self-sufficient. But because my machines are supported by Expand and Mitsubishi Electric, I know that if I do need help, I’ll have it,” says Tai. “However, because the machines and controls are so good, I don’t think I’ll need that help too often.”

Tai was so pleased with his increased productivity that he ordered two new five-axis machines to replace two of his four-axis units. The new machines will face each other. Between them will be a new LoadMate Plus. Its robot will have a longer reach, making it possible to load both machines with one cell. 

“Tai Le is a great example to other small outfits,” says Singh. “He knows that if you don’t invest, you can’t grow your business.”

For more information on machine tending, read these articles:
Mobile Cobot Workstation Integrates With Larger Systems
A Roundup of New Robots
Cobot Automates Machine Tending