IPR has reduced programming time by one-third thanks to Tebis

IPR products are used all over the world. Customers appreciate that the robotics experts from Kraichgau, Germany offer a broad portfolio of standard components in addition to customized solutions for sophisticated special and large-scale projects. One key success factor is their high level of vertical integration: The development, manufacturing and application departments work together very closely.
“Our product portfolio covers a wide range of standard and special grippers, 7th axes, robot load limiters, axis compensation modules and tool changers for robots,” explains Daniel Schiefer, Deputy Production Manager, CAM programmer and machinist at IPR.

Our company stands for robust, reliable and technically high-quality components that significantly simplify and accelerate automation tasks for everyday routines.

To streamline the process chain, machining should be automated as much as possible and take place completely in one setup. This is designed to optimize milling center running times and make best possible use of the available capacities. Machine operators should be effectively supported, especially during the loading and unloading of machines. Two of the 5-axis machines already have robots for workpiece handling, and the turning-milling center has a fully automatic loading cell with robot.

Most of the workpieces are typical 2.5D parts with tolerances generally in the range of one hundredth of a millimeter. Initially, workpieces were programmed entirely on the machine – which was still easily possible with the company’s typical range of parts at the time. 

That was now more than a decade ago. Today, IPR has several in-house Tebis licenses. “We now create around 99 percent of our 5-axis programs using Tebis and around 80 percent of our 3-axis parts. Only around 5 percent of all parts are now programmed directly on the machine – and even that proportion is decreasing,” explains Schiefer.

With Tebis, we have meanwhile integrated many previously manual processes into machining directly on the machine.

In particular, reworking is minimized as much as possible. For example, many components must be absolutely burr-free. “We used to employ four assistants – a total of two full-time positions – for deburring,” explains Schiefer. “It’s not an attractive job, which is why we set ourselves the goal of ensuring that components were already burr-free when they left the machine. We have largely succeeded in this, with only one of the employees now doing deburring on a part-time basis. And two of the other assistants have completed training as machining mechanics at our company, qualifying them for more interesting jobs with more personal responsibility.”

Above all: “This reduces time-consuming routine work down to a minimum,” he adds. “Now I can concentrate on developing the programs as efficiently as possible, which benefits process reliability and machine runtimes. And Tebis saves time on programming – around one third. This allows projects to be implemented more quickly and machining processes to be carried out in a stable and economic manner – an advantage that is directly reflected in shorter throughput times and higher quality for our customers.”
To ensure that this works reliably, the experts have recorded all cutting tools including their geometrical data, combined this with cutting data for various materials, and stored it all in a database. “We primarily machine high-strength aluminum alloys, with a small proportion of our machining work involving workpieces made of steel, some even of hardened steels. And once in a while, we also machine plastic materials,” adds the machinist.

All of this is stored parametrically in the database. In addition to the tools, our machines and clamping devices are also available as digital twins.

At this point at the latest, a simulation with collision analysis in Tebis makes sense. “However, this can only be as accurate as the data we provide to the software,” says Schiefer. “In order for us to obtain truly reliable results here, it is necessary to precisely measure and record the machine and all relevant production equipment. This gives us a true digital twin that reflects reality one-to-one.”
While milling is currently still being done with Tebis 4.0, those responsible for CAM implementation in the turning and turning-milling area have purchased the current 4.1 version. “The question of whether to purchase a different CAM program for turning did not arise for us,” emphasizes the deputy production manager. 

Tebis has made great developmental leaps in recent years, especially in turning and turning-milling operation. We feel that we are in very good hands with our software partner. In addition to the software, this is mainly due to the highly competent support we receive. We frequently used this support, especially at the beginning. But even today, we still regularly exchange ideas with the Tebis experts.

With Tebis, the experts in robot peripherals know they are perfectly equipped for the future. “Tebis widens the door to significantly more complex machining operations – we will take this into account when purchasing new machines moving forward,” predicts the deputy production manager. “For us, this means that we will not only be able to machine existing parts with greater speed and precision but, in the process, will also develop new skills for entirely novel types of parts.”
This is also necessary given how customer demands are constantly growing and tailored-made solutions are increasingly called for. “We are therefore continuing to evolve dynamically – and we benefit from the knowledge that Tebis provides to us as a reliable partner at our side,” Schiefer concludes.

From our perspective, Tebis really stands out among CAD/CAM providers. And it’s a good feeling for us to know that we already have the right in-house partner for the next development stages. Moving forward, this allows IPR to support our customers even more quickly and flexibly with high-performance robotics and automation solutions.