Automation built into the system. Efficiency in the results.

Compact Automation for Indexable Inserts

Indexable inserts are a fixed part of metal cutting. The catch: handling them is time-consuming. With »micBox«, ZOLLER offers a standardized automation solution that flips or exchanges indexable inserts on milling tools. Tool preparation costs are reduced, and competitiveness increases.

The 6-axis robot precisely grips the indexable insert, lifts it from the storage pallet, and places it onto the freshly cleaned insert seat of the carrier tool. The next steps: pick up the mounting screw, lightly grease it, and tighten it, then place the tool aside. With »micBox«, ZOLLER offers a standardized, compact automation system for handling indexable inserts. The space needed: approximately three square meters of surface. Capabilities: tools up to 420 mm in length, 340 mm in diameter, and with a weight up to 20 kg.

»micBox« – Quick Exchange of Indexable Inserts

“This automation system is very efficient and will revolutionize tool preparation,” says Kunal Singh, who is responsible for project management and automation at ZOLLER. “For a complex tool like a hob cutter, it takes a skilled technician about 35 minutes to exchange all the inserts. »micBox« is done in 12 minutes and 30 seconds,” he says, giving an idea of the performance of ZOLLER’s new automation system. Depending on the tool, the assembly time is reduced by 60 to 70 percent compared to the manual process.

Optional—first check for wear, then flip or exchange

»micBox« solves a problem that plagues many machining operations. Tools with indexable inserts require regular, professional handling. This takes time and ties up skilled workers. Those who do not continuously maintain their tools will quickly feel the consequences: quality losses and, in the worst case, even damage to the workpiece and the tool holder if a cutting edge breaks off. »micBox« can reduce such risks. Optionally, a camera system and the AI function »wearCheck« perform an inspection of each cutting edge for wear and tear. This provides double safety: worn inserts don’t make it onto the machine, while intact inserts remain in use.

Documentation for Indexable Cutting Inserts

As an additional option, »micBox« can generate comprehensive documentation of the tools. Via the link to ZOLLER Tool Management »TMS Core«, an optional tool records for each tool when »micBox« which insert was rotated to which cutting edge or when the insert was replaced. The exchange of the mounting screws is also included in the data record, as is the tightening torque. “The user can define the tightening torque in advance and also specify at what intervals »micBox« should exchange the screws,” explains Kunal Singh, adding:

“For suppliers in highly regulated industries such as aerospace, engine manufacturing, or medical technology, this documentation demonstrates high process quality, provides additional data for quality management, and supports tool traceability.”

Combined Automation—Plate Assembly Plus Presetting & Measuring

»micBox« already offers significant efficiency advantages as a stand-alone solution. This indexable insert specialist really comes into its own when it works in tandem with ZOLLER’s new automation cell, »coraVarion«. Together, they handle the assembly of indexable inserts, presetting and measuring on one of ZOLLER’s premium machines, and providing tools on a ZOLLER »smartPallet«. This system guarantees high automated throughput, precise processes, and a seamless transition between tool preparation and shop floor logistics.

Greater Competitiveness and High Repeatability 

“At locations with high labor costs, manual tool handling reduces profitability and thus international competitiveness,” says Christoph Zoller, CEO of ZOLLER. Even as a stand-alone solution, »micBox« reduces the impact of labor costs. When used in combination with »coraVarion«, the positive effect is amplified.

“If tool preparation is extensively automated, we no longer compare labor costs across different markets, but rather machine costs. The hourly rate for »micBox« or »coraVarion« is similar everywhere. The labor cost advantage in many markets decreases. Our automation is therefore of interest to anyone who wants to increase their competitiveness. Thanks to standardization, it is very attractively priced and offers the high repeatability that is especially essential for high-tech industries,” says Christoph Zoller.

Only from ZOLLER – Automation Built into the System

»micBox« and »coraVarion« expand the ZOLLER system in the area of tool preparation and make it possible to use significant optimization potential. ZOLLER customers can start deploying a unique automation team in their production facilities that lifts tool preparation to a new level of efficiency.