The Cut Scene: Integrated Machine Tending Cell Using AI, Vision and AMRs

This modular KUKA automation cell integrates advanced bin picking, machine tending, and mobile material handling to support both job shops and high-volume operations. A vision-guided robot retrieves randomly oriented billets from bins and loads them onto mobile trays. Autonomous mobile robots (AMRs) shuttle trays between stations, with AI-powered fleet software orchestrating movement, avoiding collisions, and adapting to dynamic shopfloor conditions.

1. Bin Picking Robot

A KUKA KR CYBERTECH robot, paired with Roboception 3D vision and KUKA.SmartBinPicking software, extracts 3” x 2” steel billets from bins and places them onto portable trays. The robot features a Schunk tool changer, Magswitch magnetic gripper, and Festo-controlled end-of-arm tooling.

2. Vision System

Roboception’s rc_viscore stereo sensor and rc_reason CADMatch software enable accurate part recognition and retrieval. CADMatch blends AI with geometric algorithms, working in tandem with KUKA.SmartBinPicking to locate and pick parts from unstructured bins.

3. AMRs for Tray and Tote Handling

Two KUKA KMP 1500P AMRs, managed by AMR.Fleet software, transport trays and totes between cell locations. The tray-handling AMR includes an integrated lift module; the tote-handling unit features a conveyor for hands-free bin transfer. Both use KUKA’s diffDrive system and 360° lidar for safe navigation in live production environments.

4. Fleet Management Software

KUKA.AMR Fleet Manager oversees AMR traffic, coordinating with all system components. The software dynamically replans routes in real time, avoiding obstacles and minimizing idle time between the two staging conveyors.

5. Machine Tending Robot

A KR CYBERTECH nano robot equipped with Zimmer dual-servo grippers loads billets into a CNC turning center. The lathe-tending setup from MAIROTEC enables compact, fenceless automation.

6. CNC Machine Tool

A Goodway GLS-2000LYS horizontal lathe from Merrifield Machinery Solutions performs the turning operations. With twin spindles and a top-mounted turret, the machine supports multi-tasking automation. Safety and wireless I/O communication are handled by solutions from Banner Engineering.