With the transfer of the robot system RS 1 to the GEN2 platform, the machine factory Berthold HERMLE AG is consistently expanding its automation portfolio. After the RS 2, the compact RS 1 has now also been technologically updated.
The system particularly addresses users with diverse production and increasing demands for unmanned operating times, flexibility, and process reliability.
Combined cell for pallet and workpiece automation
The RS 1 GEN2 is designed as an integrated automation cell for handling pallets, workpiece carriers, and individual parts. The focus is on flexible use in different manufacturing scenarios – from single part production to small and medium series.
Characteristic is the combination of:
- automated pallet handling
- integrated parts handling
- main-time parallel setup
Through automatic gripper and clamping tool changes, as well as the ability to implement various machining strategies in parallel, high machine availability is achieved.
Scalable system architecture
A central feature of the RS 1 GEN2 is the modular and scalable architecture. The system can:
- be operated with one or two machines
- be retrofitted from single to dual machine operation
- be supplemented with additional peripherals such as storage modules, measuring machines, washing systems, or AGV systems
The connection is possible to different HERMLE machining centers, allowing for flexible cell configurations.
Compact design with high accessibility
With a footprint of approximately 12 m² (4.25 x 3.00 m), the RS 1 GEN2 is one of the most compact solutions in its class. Despite the small footprint, access to the machine workspaces is fully maintained – both in single and dual machine operation.
The nearly fully glazed enclosure improves process visibility while simultaneously supporting the safety concept during manual interventions.
Central handling system with high load capacity
The centerpiece is a centrally located 6-axis robot with a maximum load capacity of 60 kg. By being positioned on the system platform, it reaches all relevant stations:
- machine workspaces (up to two)
- storage modules
- setup areas
- transfer stations
This enables short distances, high dynamics, and stable cycle times.
Intelligent storage system with dynamic occupancy
The storage system is based on a software-based, adaptive storage strategy. Workpieces and pallets are automatically and space-optimized sorted without fixed assignments ("chaotic storage").
The advantages:
- maximum utilization of available storage space
- reduced setup efforts
- no manual shelf configuration
The number of available storage modules adapts to the respective system configuration.
Integrated measurement technology for process-safe loading
The setup area system is equipped with laser monitoring that checks workpiece heights and widths before storage. This ensures that only validated components enter the automated material flow.
At the same time, the control recognizes free space capacities
and optimizes with each active transport whether there is a more optimal storage location.
Wide range of gripper and clamping systems
For adaptation to different part geometries and manufacturing strategies, a comprehensive portfolio is available:
- Electric grippers ELRG
- Standard and hybrid grippers
- Single and double grippers
- NSR grippers for pallets up to 60 kg
- automatic jaw changes for vises
This allows both pallet and individual part processes to be combined within a cell – even in parallel on separate machines.
Adaptive control software
The system control takes over the complete coordination of the processes:
- Order management
- Material flow control
- Condition monitoring
- dynamic prioritization
In case of disruptions, for example due to tool breakage, the system implements automatic diversion strategies and continues alternative machining orders. An integrated preview supports the operator in planning over several days.
Conclusion: High flexibility on minimal space
With the RS 1 GEN2, HERMLE positions a compact, highly modular automation solution for demanding manufacturing environments. Particularly noteworthy are:
- high flexibility with changing components
- scalable machine connection
- intelligent storage and control concept
- compact design with full functionality
Thus, the system specifically targets companies that need to economically automate their production while remaining flexible to changing requirements.
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