Automation in deep hole drilling ranges from simple part loaders to fully integrated production cells. The level of automation you need depends on your production volume, part variety, and labor availability.
I’ve worked with manual machines, semi-automated cells, and fully automated lines. Each has its place.
Levels of Automation
| Level | Description | Typical Volume | Labor |
|---|---|---|---|
| Manual | Operator loads, starts, unloads | Up to 500 parts/year | 1 operator per machine |
| Semi-automated | Operator loads, machine cycles automatically | 500-5000 parts/year | 1 operator per 2 machines |
| Automated cell | Robot loads and unloads, machine cycles automatically | 5000-20,000 parts/year | 1 operator per 4-6 machines |
| Integrated line | Full automation with conveyor, gantry, or robot | 20,000+ parts/year | 1 operator per line |
The jump from manual to semi-automated is usually the easiest and has the fastest payback.
What Automation Costs
For a single-spindle gun drilling machine:
| Automation Level | Additional Cost | Typical Payback |
|---|---|---|
| Auto-cycle (CNC) | Included in machine cost | Immediate |
| Parts counter / tool monitoring | $2,000-$5,000 | 3-6 months |
| Automatic tool changer | $15,000-$30,000 | 6-12 months |
| Robot loading cell | $60,000-$120,000 | 12-24 months |
| Gantry loading system | $80,000-$150,000 | 18-36 months |
| Full integrated line | $200,000+ | 24-48 months |
The payback depends on your labor cost and shift pattern. Higher labor costs and multi-shift operations get faster payback.
What to Automate First
If you’re new to automation, I recommend starting with the operations that are most repetitive and least skilled:
- Machine cycle. Automatic pecking cycles, spindle start/stop, and coolant on/off are basic features on any CNC machine.
- Tool monitoring. Spindle load monitoring and tool breakage detection prevent costly crashes.
- Part loading. If you run the same part in high volume, automated loading is the next step.
- In-process gauging. Automatic diameter measurement during the cycle reduces inspection time.
Robot Loading
Robot loading cells are the most common automation for mid-volume production. A robot picks a raw part from a conveyor or pallet, loads it into the machine, and removes the finished part.
For deep hole drilling, the robot needs to handle parts that may be long and heavy. A 20kg shaft requires a robot with sufficient reach and payload capacity.
I’ve seen robot cells that operate unattended for hours, loading parts and checking them with an in-process gauge. The operator’s role shifts from loading parts to managing the cell and checking occasional samples.
Gantry Loaders
Gantry loaders are an alternative to robots for longer parts. A gantry has a horizontal beam with a vertical arm that moves along the beam. The arm picks parts from a staging area and loads them into the machine.
Gantries are less flexible than robots but often more reliable for simple pick-and-place operations. I’ve seen gantry systems that have operated for years with minimal maintenance.
In-Process Gauging
In-process gauging measures the bore diameter during the drilling cycle. The gauge is mounted on the machine and measures the hole immediately after drilling.
The benefits:
- Immediate feedback on hole quality
- No waiting for off-line inspection
- Automated adjustments to compensate for tool wear
- Documentation of every hole
I’ve seen in-process gauging systems that adjust the tool position based on the measured diameter. The system compensates for tool wear and maintains consistent hole size throughout the production run.
When Automation Doesn’t Pay
Automation isn’t always the right answer:
- Low volume. If you run fewer than 500 parts per year of a given design, the setup time for the automation system exceeds the running time.
- High variety. If every part is different, the automation system spends more time changing over than running.
- Complex parts. If the part requires operator judgment for loading, clamping, or inspection, automation may not be feasible.
- Low labor cost. If labor is cheap and available, the payback on automation is longer.
I’ve seen shops buy expensive automation systems that sit idle because the work mix changed. A flexible manual machine is more profitable than an automated machine that’s not running.
Key Takeaways
The best approach to automation is to start with the basics and add automation as the volume justifies it. A CNC machine with automatic cycles and tool monitoring is the foundation. Add part loading automation when you have steady production of a specific part.
The shops that automate most successfully are the ones that have stable production volumes and consistent part designs. Automation amplifies productivity, but it also amplifies the problems of unstable production. For more on matching automation to machine capabilities, see CNC Controls for Deep Hole Drilling and Multi-Spindle Deep Hole Drilling.
Key Takeaways
- Start with basic CNC automation (auto-cycle, tool monitoring) before investing in part loading.
- Semi-automated operation is the easiest automation step with the fastest payback.
- Robot loading cells cost $60,000-$120,000 with 12-24 month payback typical.
- In-process gauging provides immediate feedback and can compensate for tool wear automatically.
- Automation does not pay for low volume (under 500 parts/year), high variety, or complex parts.
- The most successful automation shops have stable production volumes and consistent part designs.