Think modular, automate flexibly – an interview with Cellro
Production processes are becoming ever more complex – component diversity, short throughput times and increasing demands for flexibility require new approaches in automation. The Dutch automation specialist Cellro is responding to this development with a modular automation kit that can be used independently of the machine manufacturer.
Together with GRESSEL, Cellro relies on the proven R-C2 clamping system, which can be seamlessly integrated into the robot cells. This combination not only enables reliable workpiece handling, but also complete 6-sided machining – automated, compact and efficient.
Find out what this solution looks like in practice, what role software and flexibility play and why smaller series in particular benefit from the interaction between Cellro and GRESSEL in this interview.
Could you briefly introduce yourself and your company?
Cellro has been developing and building robot cells for the automation of processing machines for over 20 years. From the very beginning, the focus has been on the flexible processing of small product series. Today, we offer a broad portfolio of standard solutions from which we implement efficient automation solutions for existing and new machines, taking into account customer requirements and in close consultation.
What are the five top benefits of your automation solution?
- Extensive portfolio of standardized automation solutions
- Can be used independently of the machine manufacturer
- Modular combination of workpiece, pallet, clamping device and tool change
- Own branches in the Netherlands and Germany as well as a strong partner network throughout Europe
- Continuous further development in mechanics and software with a view to shopfloor excellence
Does your automation solution enable the complete processing of a workpiece on all six sides?
Absolutely. The implementation of the GRESSEL R-C2 6S strategy within our robot cells enables the complete 6-sided machining of a workpiece – without manual intervention.
What batch sizes is your automation solution suitable for and what impact does this have on efficiency?
This depends heavily on the product mix and the cycle times. In principle, even single items can be automated. In practice, we often see batch sizes between 10 and 100 pieces. A major efficiency advantage is that the adjustable R-C2 clamping system also functions as a gripper – so there are no special requirements for the machine’s clamping devices. The zero-point clamping system can also be operated by the robot.
How does your automation help to reduce set-up and changeover times?
Very clearly. Compared to the classic pallet strategy, the manual effort is massively reduced: the time-consuming insertion of components into clamping devices is no longer necessary and the number of pallets required is also significantly reduced. All in all, the R-C2 strategy is both investment and operating cost friendly.
In which sizes and versions is your automation solution available?
The R-C2 | 6-side system is available in our portfolio for the Xcelerate X20 and X35 models – for robots with a handling weight of up to 35 kg.
What are the advantages of a compact automation solution in production?
Free access for manual activities is particularly important when loading from the front of the machine. Even when loading from the side, a compact design remains essential in order to keep the space required in production as small as possible.
How can your automation save space and increase productivity at the same time?
Productivity results from the combination of unmanned running times and greater efficiency in manned shifts. This means that machines can either be better utilized or consistent quantities can be produced by reducing the number of machines. Compared to the pallet strategy, the product change strategy with R-C2 requires significantly less storage space – with increased flexibility at the same time.
How quickly and easily can new components be integrated?
Thanks to the graphical dialog control, a new product configuration can be created in a short time. The robot movements are based on a series of simple inputs from the operator – e.g. workpiece dimensions, clamping width and desired cycle steps (centering, reversing, cleaning).
How flexible is your solution for different workpiece geometries and materials?
Very flexible: The large clamping range of our centric clamps automatically adapts to different workpiece sizes. In addition, the clamping force can be specifically adjusted depending on the process step.
What options are there for connecting to existing machines?
Ideally, the machine supports the communication of NC program numbers – this is particularly relevant for high-mix/low-volume strategies such as those pursued with R-C2. However, Cellro has also successfully integrated cells on existing machines with just a hard-wired interface – while maintaining the same high mechanical benefits.
What factors are particularly important when selecting a loading system?
The most important factor is the loading position – whether from the front or the side. The workpiece weight and component dimensions also play a role, as does the desired degree of autonomy (e.g. number of unmanned hours). These factors determine the choice of robot and the required storage capacity.
How long does it usually take for an automation solution to pay for itself?
This depends heavily on the application – but the amortization period is usually less than 24 months. Our experience shows: In typical series production, the average amortization period is around 18 months.
Is there an example of successful integration into existing processes?
Yes – in one company in the aerospace industry, machines were previously operated empty at night to keep the temperature stable. With the integration of a Cellro robot and the GRESSEL R-C2 system, the same machinery could now also be used productively at night – with consistently high precision.
What role do AI and sensor technology play in loading automation?
Artificial intelligence is a key technology of the future. Cellro has already taken this into account in the development of the “Manufacturing Intelligence” platform. This ensures secure, fast interfaces to CNCs, ERP, PLM, MES and transport systems. Data is evaluated in real time and made available in the right places – for reliable production planning today and tomorrow.
What training and support services do you offer?
We take care of the complete installation and commissioning of the robot cell. We also offer training, support with integration into existing processes and real-time remote monitoring by our service department. This means that questions or problems can often be solved directly online. We also offer optional service and maintenance contracts for maximum operational reliability.
How do you see the future of production?
In addition to the continuous further development of hardware and control systems, we see great potential in digitalization following automation. With our Manufacturing Intelligence platform, we offer the possibility of intelligently networking production processes – modular, scalable and future-proof.
Cellro B.V.
Koningsschot 41
3905 PR Veenendaal
Netherlande
Cellro GmbH
Frankenbacherstraße 32
74336 Brackenheim
Germany
