Explore PALLETECH's Modular Flexibility

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PALLETECH SYSTEM

High productivity automation system
 

We offer the PALLETECH MANUFACTURING CELL (1 level) and PALLETECH HIGH RISE SYSTEM (2, 3 level) according to your volume of production and budget.
Furthermore, the PALLETECH SYSTEM is designed for convenient system expansion after the initial installation to easily respond to increased production requirements in the future.

MODULAR DESIGN

PALLETECH EXPANDABILITY

A single machine system can be expanded - pallet stocker(s), loading station(s) and machines can be added in response to increased production requirements after the initial system installation.



FMS control/ management software - unsurpassed ease of system operation to meet sudden changes in schedule.
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MAZATEC SMS

Mazak SMS with large capacity pallet stocker
 

  • Maximum 16 machines, 8 setup stations, 240 pallets
  • Flexible system length and height layout
  • Maximum 6 types of stocker sizes available to meet your production requirements
  • Stocker crane for high speed loading / unloading
  • Loading/ unloading station for material pallets also available.
  • Loading station allows access from two directions and area sensor for safety
  • Smooth PMC controller for convenient machining management
  • System integration with ERP available
  • Software for integration with other computer network available upon request.

 

SMOOTH PMC controller machining management system

Production data and status can be monitored using the SMOOTH PMC controller management system. Fixture pallet synchronized with material pallet at loading station also available.

 

MPP (MULTI PALLET POOL)


Compact multiple pallet stocker system


The MPP (MULTI PALLET POOL ) is a new system to meet the increasing worldwide demand for automation. It is designed to provide high productivity for multiple variety, small lot production.  MOVIE
 


The operation and management of the MPP is performed by the same software used by the Mazak's FMS system, which is highly regarded worldwide for its ease of operation and high productivity   MORE
 


  • Compact floor space for multiple pallet stocker
  • Stocker can be expanded up to 18 pallets after the initial installation of a MPP with 6 pallets in response to increased production requirements
  • 600kg max. load (pallet weight not included, depends on machine specifications)
6PC
3 pallets×2 levels
(6 pallets +
1 loading station)
12PC
6 pallets×2 levels
(12 pallets +
1 loading station)
18PC
6 pallets×3 levels
(18 pallets +
1 loading station)
 
 
Compatible machines and
specifications
VARIAXIS i-600 VARIAXIS i-700 VARIAXIS i-700T
Number of pallets 6 / 12 / 18
Pallet size 400 mm × 400 mm
(15.75" × 15.75")
500 mm × 500 mm
(19.69" × 19.69")
Φ610mm(Φ24.02")
Max. load (without pallet) 300 kg (661 lbs) 600 kg (1323 lbs)
Max. workpiece size (without pallet) Φ600 × H425 mm
(Φ23.62" × 16.73")
Φ730 × H500 mm
(Φ28.74" × 19.69")

 

 

  • Compact floor space for multiple pallet stocker
  • Stocker can be expanded up to 18 pallets after the initial installation of a MPP with 6 pallets in response to increased production requirements
  • 500kg max. load (pallet weight not included, depends on machine specifications)
6PC

 

3 pallets×2 levels
(6 pallets +
1 loading station)
12PC

 

6 pallets×2 levels
(12 pallets +
1 loading station)
18PC

 

6 pallets×3 levels
(18 pallets +
1 loading station)
 
 
Compatible machines and
specifications
HCR-5000S
Number of pallets 6 / 12 / 18
Pallet size 500 mm × 500 mm
(19.69" × 19.69")
Max. load (without pallet) 500 kg
(1102 lbs)
Max. workpiece size (without pallet) Φ700 × H643.6mm
(27.56" × 25.34")

 

 

  • Compact floor space for multiple pallet stocker
  • Stocker can be expanded up to 16 pallets after the initial installation of a MPP with 10 pallets in response to increased production requirements
  • 700kg max. load (pallet weight not included, depends on machine specifications)
 
10PC
5 pallets×2 levels
(10 pallets +
1 loading station)
16PC
8 pallets×2 levels
(16 pallets +
1 loading station)
 
Compatible machines and
specifications
HCN-4000 HCN-5000,HCN-5000/50
Number of pallets 10 / 16
Pallet size 400 mm × 400 mm
(15.75" × 15.75")
500 mm × 500 mm
(19.69" × 19.69")
Max. load (without pallet) 400 kg (882 lbs) 700 kg (1543 lbs)
Max. workpiece size (without pallet) Φ630 × H900 mm
(Φ24.8" × 35.43")
Φ800 × H1000 mm
(Φ31.50" × 39.37")

 

RCC

Management software for the robot cell


Dedicated management software for high-mix, low-volume production utilizing a robot ― operator can easily make the production schedule for extended periods of operation and check resources on the dedicated screen. [OPTION]

Functions to reduce automatic operation setup time

 

Resource check

  • Prevent missing items which will stop automatic operation
    Smooth RCC displays missing programs and tools thanks to resource check. During automatic operation, real-time tool simulation displays tools which have short remaining tool life to indicate which tools must be setup.

 

 

 

Robot setup assist

 

      
    • Fast and easy robot setup
      Automatically makes robot programs by inputting length of material, diameter and robot hand specification into the MAZATROL SmoothAi. For exceptional ease of operation, this conversational programming eliminates robot teaching.
     

TA (Turn Assist)

Mazak's automation system for CNC turning centers

Automation system for turning centers without complicated robot teaching


Integrated system - hardware and software

Designed for safety and ease of operation

If entry of a person into the system area is detected while the robot is operating, its motion will decelerate and stop. Safety fence not required on system front and right side.

 
 

Automatic system operation

  • Automation from loading raw material to unloading finished workpieces
    Turn Assist consists of a robot, Parts stocker and Smooth TURN ASSIST (system software).
  • Stocker
  
  • Perform automatic operation over extended periods since the stocker can stack multiple levels of material and finished workpieces
 



Wide range of specifications to meet your requirements

       


 
Specifications TA-12/200 TA-20/270 TA-35/270
Material Max. material
diameter
Φ200 mm Φ270 mm Φ270 mm
Max. material
weight
7.0 kg (3.5 kg X 2) 14.0 kg (7.0 kg X 2) 26.0 kg (13.0 kg X 2)
Dimensions Width × Depth
× Height
1489 × 1460 × 2456mm 1920 × 1460 × 2456mm 1920 × 1460 × 2456mm
 
 

Shaft workpiece  TA-20/270, TA-35/270

  • Can load the shaft workpiece and unload the finished workpiece

    Comprised of a 4-jaw gripper for shaft workpiece, work stand for stocker and Smooth TURN ASSIST(system software)

  •       

     
    Specification for shaft workpiece TA-20/270 TA-35/270
    Diameter Φ10 ∼ Φ80 mm
    Length 200 ∼ 800 mm
    Max. Weight 14 kg(Should not be unbalanced) 25 kg(Should not be unbalanced )
     
    Note : The maximum length of the material depends on the distance between centers, the door opening area, the chuck and jaws.
    Diameter difference between material and finished workpiece is within 18mm at the maximum.
    Please contact us for further information.
     
     

    Smooth TURN ASSIST (system software)

     By inputting raw material and finished workpiece data,
     Smooth TURN ASSIST prepares the robot for operation

    • Complete a workpiece setup in just 10 minutes

      The built-in CNC system software (Smooth TURN ASSIST) provides easy system setup without requiring an operator familiar with robots. Using the preset outer diameter, length, and machining quantity of the material and finished part instructions are displayed for 1) loading the stocker with material, 2) mounting the finished workpiece positioning support rod, and 3) mounting the robot hand chuck jaw. Setting the material height position is automatic.

    •  
       

      System introduction

       TA can be installed in front of the machine and start operation immediately after being installed.

       
       

      Note : This system is compatible with machines equipped with MAZATROL SmoothG.
      (QUCIK TURN with SmoothC can be field-installed.)
      The following TA compatible optional equipment is required on the machine side.
      ・Spindle orientation
      ・Automatic door
      ・TA cable connection port
      ・Advanced robot interface(EtherNet/IP)

Tool transport system


The tool transport system automatically transfers tools
from a central tool stocker directly to the tool magazines of machines in a system.


Tools are automatically delivered to machines based on the machining schedule in order that operation will not be stopped due to missing tools. The operator can load setup tools into the single central tool stocker which supplies tools to multiple machines in a system.
For convenient tool management, the Smooth PMC controller performs production simulation based on the current system load and machine status to forecast required tools and expired tools to be removed.
 

Example system

A unique tool can be automatically shared between multiple machines resulting in lower tooling expense.

Gantry Loader

Ease of workpiece transfer and loading/unloading
 

High speed, high accuracy workpiece transfer and loading / unloading for unmanned operation over extended periods of time. Different specification work loader hands and work conveyors are available for a wide range of Mazak machine tools.

CNC turning centers ・Multi-tasking machines


GL series for extended periods of automatic operation

  • High speed gantry loader ensures higher productivity
  • 2-pallet workpiece conveyor at front and rear allows setup of next job during machining of the current one
  • Wide variety of gantry loaders to meet your production requirements
  •  
    Applicable machines Gantry loader
    CNC turning center
    MULTIPLEX W series
    GL-100 / GL-150 / GL-200 / GL-300 / GL-400
    Multi-tasking machine
    INTEGREX i
    series
    GL-50F / GL-75F / GL-100F / GL-150F / GL-200F /GL-300F / GL-400F / GL-500F

 

 

 


New gantry loader meets a variety of automation requirements

  • Flexible installation - conveyor can be located on machine right or left side, measurement equipment can be added and can connect 2 machines

  •     

  • By adding automatic door and robot I/F, gantry loader can be field installed on QUICK TURNs
  • Different specification work loader hands and gantry loaders are available to meet a wide range of production requirements
  •  
    Applicable machine Gantry loader
    CNC turning centers
    QUICK TURN series*
    QT-COMPACT series
    GL-30 / GL-50 / GL-100 / GL-150 / GL-200 / GL-300

    *Not available for the QUICK TURN 400,450 series


 

 

FF Horizontal machining center series

Compact production line with gantry loader

  • Designed for large volume production for automotive components
    -for the machining of components such as engine blocks and cylinder heads



TOOLTECH


Compact rack-type magazine with large storage capacity

Tools are organized according to tool length and diameter for high space efficiency.
The high speed tool loader carries tools to the automatic tool changer.

206 tools can be stored in approximately the same floor space as a 120 tool chain magazine.

Tool cart

  • Easy loading of tools into the tool cart that is directly inserted into the tool dock
  • Loading/unloading tools outside the magazine ensures safe setup operation
  • Convenient transportation by tool cart

Large tools

  • Large tools that normally require manual loading are handled by the automatic tool changer
  • Max. tool diameter Φ360 mm (Φ14.17"), max. tool length 1000 mm (39.37"), max. tool weight 40 kg (88 lbs), max. tool moment 80 N・m (59 ft・lbs)
  • 40 kg (88 lbs) tools can easily be loaded with the heavy tool fixture

Extensibility

  • 70 tools can be added by the 1260 mm (49.61") extension at the rear of the magazine
  • Designed for convenient system extension after the initial installation

Applicable models

HCN    HCN-6000, HCN-6800, HCN-8800, HCN-10800, HCN-12800   
μ Series    μ-8800, μ-10800   
MEGA    MEGA 8800   
INTEGREX i-V    INTEGREX i-630V/6, INTEGREX i-630V/6S   
VORTEX i    VORTEX i-630V/6, VORTEX i-630V/6S, VORTEX i-800V/8, VORTEX i-800V/8S   

SUPERFLOW V30C-J


High-pressure coolant system for higher efficiency and productivity

  • While normal flood coolant may fail to reach the cutting zone, SUPER FLOW ensures direct delivery to the cutting edge, reducing temperatures and improving tools’ cutting action
  • SUPER FLOW helps to create small chips and efficiently evacuating them from the cut where chips are removed by the coolant resulting in extended tool life
  • SUPER FLOW prevents coolant vaporization by heat and delivers coolant directly between the tool and workpiece, improving lubrication, tool life and surface finish
  • Coolant pressure easily set by M-code (pressure range from 0 to 7 MPa)