Automation — Palletized handling

Palletized handling automation refers to systems that automatically transfer pallets carrying workpieces between a magazine and one or more machine chucks, without manual operator involvement during each cycle. The core benefit is that machines continue to cut during periods when no operator is present, including nights and weekends. This increases effective machine utilization, reduces lead times and accelerates the return on the capital invested in the machine itself.

All SYSTEM 3R palletized handling systems support a broad range of machine technologies. Depending on the product, compatible technologies include milling, die-sinking EDM, wire EDM, laser, grinding, CMM and washing. The WorkPal 1, WorkPartner 1+, Transformer T3 series and Transformer 6-Axis Robot all share this multi-technology compatibility through SYSTEM 3R's open architecture approach. The Collaborative Robot C6-20L currently supports milling, wire EDM, laser, CMM and washing applications.

The right system depends primarily on payload, the number of machines to be served and the required magazine capacity. The WorkPal 1 serves one machine, handles up to 50 kg and offers up to 60 pallet positions: it is the right choice for a first automation installation with a compact footprint. The WorkPartner 1+ serves up to two machines, handles up to 100 kg and accepts up to three magazines in any combination, making it well suited to mixed-technology cells. The Transformer T3 series scales to 12 machines and 600 kg and is designed for cells that need to grow over time. The Transformer 6-Axis Robot addresses the heaviest and most complex handling requirements up to 700 kg and 3,400 mm reach.

Collaborative Robot C6-20L: 20 kg including gripper, pallet and workpiece. WorkPal 1: 50 kg. WorkPartner 1+: 100 kg (80 kg when a load and drain station is in use). Transformer T3-100: 100 kg. Transformer T3-150: 150 kg. Transformer T3-200: 200 kg. Transformer T3-600: 600 kg. Transformer 6-Axis Robot Model 70: 70 kg. Model 165: 165 kg. Model 210: 210 kg. Model 360: 360 kg. Model 700: 700 kg.

SYSTEM 3R automation systems support up to 20 different tooling systems including Macro 54, Macro 70, MacroPT, Macro 116, MacroMagnum, Macro WEDM, Matrix 110, Matrix 142, GPS 70, GPS 120, GPS 240, Dynafix, Delphin, ITS 50, ITS 72, ITS 115, ITS 148, UPC and PalGrip. The number of tooling systems that can be used simultaneously within one cell depends on the product: the WorkPal 1 supports one tooling system per magazine, the WorkPartner 1+ supports two (one per magazine), and the Transformer T3 and Transformer 6-Axis Robot support up to five tooling systems per cell. Tooling from other manufacturers can also be accommodated on the Transformer systems.

The ID system uses code carriers mounted on pallets and antenna readers at key positions in the magazine and cell. When a pallet is placed in a magazine slot, its identity and position are registered. When a pallet is transferred to a machine or returned to the magazine, the cell management software updates the status automatically. This prevents a pallet already in the machine from being occupied again in the magazine and ensures that the correct NC program is associated with the correct workpiece at all times. Presence detection adds a second layer of safety by confirming that a magazine position is physically occupied before the system attempts a transfer.

Yes. The Collaborative Robot C6-20L, WorkPartner 1+ and Transformer T3 series all support integration with SYSTEM 3R AMR units. The AMR replenishes the automation cell magazine with fresh pallets and removes completed workpieces, extending unattended operation beyond the capacity of the onboard magazine. For the Collaborative Robot C6-20L and WorkPartner 1+, WorkShopManager 5 and the ID system are required for full AMR support. The Transformer T3 systems include a dedicated AMR bay with docking station and lifter as a standard accessory option.

WorkShopManager 5 (WSM 5) is the primary cell management software for all SYSTEM 3R palletized handling systems. It covers three operational phases. In preparation, the Product Data Manager is used to create orders, assign NC programs and retrieve offset values before releasing work to the cell. During execution, CellManager tracks pallet ID codes and magazine positions, builds and maintains priority lists, starts available jobs automatically and records machining times and order status. For monitoring, the Dashboard provides real-time visibility of cell and machine status, and enables analysis of utilization and order data. WorkShopManager 3 and EasyCellManager are available as alternative software options for installations with simpler requirements.

No. The Collaborative Robot C6-20L is built around CRX cobot technology with hardware-enforced force and speed limits. This allows the cobot to operate safely in close proximity to personnel without the protective fencing required around conventional industrial robots. The built-in safety architecture reduces the floor space and infrastructure needed for the cell. When the AMR feature is activated, a 2D vision system on the cobot is used to identify pallets on the AMR, adding an additional layer of process integrity.

Both systems are designed from the outset for incremental growth. The Transformer T3 concept is structured around four steps: begin with a single machine, add a second machine or additional magazines, extend the rail to serve further machines, and evolve the cell layout as technology or volume requirements change. The standardized module approach means that components installed at the beginning remain part of the expanded system. The Transformer T3 scales from one machine to a 12-machine rail cell, with a maximum rail length of 30 m. The Transformer 6-Axis Robot follows the same scalable logic, accommodating up to 12 machines in a linear configuration across rail lengths up to 30 m with the heavy rail option.