In context
In October 2024, as automotive manufacturers intensified efforts to improve sustainability and cost efficiency, demand was growing for large structural components made from lightweight metals. These parts, such as underbodies and battery trays produced via megacasting or stamping, required advanced machining solutions that could handle their size while maintaining precision and reducing energy consumption.
What was reported
Comau introduced SmartReach, a robotic work cell designed for efficient machining of large lightweight components. Unlike traditional robot machining units, SmartReach is built as a CNC machine with a linear X axis, reinforced rotary axes with double encoders, and a configuration that delivers high-end CNC-level performance in dynamics, stiffness, and precision. It enables 5-axis continuous machining, allowing a single setup to access compound angles and any side of multifaceted parts without frequent angular head changes, which is critical for megacasting to avoid deformation and tolerance loss.
The modular structure supports mono, twin, or multi-spindle configurations, with frames extendable without limit and options for various turntable setups. The standard single-frame configuration offers a stroke of 3000x1890x1000 mm. This flexibility adapts to different part sizes and production needs. Real 5-axis machining with CAD/CAM and G-code programming facilitates fast model changes. Maintenance is simplified with ground-level access, reducing mean time to repair (MTTR) compared to market standards.
SmartReach supports MQL or dry machining, reducing coolant use and waste. Its architecture, aligned with Comau's ESG strategy, consumes significantly less energy than traditional vertical or horizontal CNC machines, achieving energy savings of up to 40 percent. The solution targets automotive, aerospace, and energy industries.
Why it mattered
SmartReach represented a shift toward more sustainable and flexible machining for large lightweight parts, addressing the automotive industry's need for cost-effective, energy-efficient production. Its modular, reconfigurable design and reduced energy footprint offered a path to more resilient and environmentally friendly manufacturing lines, potentially influencing future machining cell designs across industries.
“SmartReach Comau, which reflects our increasing focus on diversification, will allow us to address important markets for which high flexibility and high precision are non-negotiable.”
Source: Robotics & Automation News (roboticsandautomationnews.com) · Published 2024-10-15 · “Comau builds robotic work cell that can machine large parts using about half the energy”