At ZSO Zerspanungs und Systemtechnik GmbH in Oberstaufen, Kadia has implemented three ‘Deburr-Automation-Cells’. The function of these systems includes not only deburring workpieces, but complete automated handling of parts. European Precision Machines Ltd is the UK agent for Kadia solutions.

For ZSO managing director Carsten Binder, the project was particularly important as it involved the handling and deburring of grey cast iron housings for mobile hydraulic pumps weighing up to 26 kg – heavier than parts usually processed by the company.
“Our plan was to have a robot carry out all the recurring processes,” he says. “Deburring would also be possible on the machine tool, but a robot is a far more cost-effective solution.”

The Kadia proposal was based on a six-axis robot with a payload of 120 kg and a reach of 2.5 m, supplied completely from a single source. Kadia’s scope of supply included process development, the robot, cell, gripper, deburring stations and tools. Not to forget, of course, the sequence programming with all safety-relevant designs. Kadia delivered the first automation cell in April 2019, a second in September 2019 and a third in January 2020.

Notably, the automation cells had to be connected to three identical Heller H5000 machining centres. ZSO had gradually purchased several of these four-axis machines (already equipped with robot interfaces) especially for the pump housings. The robots had to carry out loading and unloading of the machine tools, as well as the deburring, within the machining cycle time (around 20 minutes).

“It’s important for our customers that we were able to increase process reliability and thus produce quality deburring results,” says Binder. “All edges are now deburred absolutely evenly and according to customer requirements; there are no variations in the execution. In addition, the robot never forgets an edge or thread, so reworking is a thing of the past.”

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