Engineering precision: Advancing robotic automation for heavy-duty applications
03/09/2025 Rollon
Meeting the challenge of modern manufacturing
As UK manufacturers adapt to rising productivity demands, safety standards, Industry 4.0 trends, and the transformative potential of robotics, the ability to move heavy loads with precision and efficiency has become more important than ever, especially in sectors such as energy, petrochemicals, and heavy equipment. These applications demand more than just powerful robots; they require robust, highly adaptable motion solutions that can safely extend a robot’s operational range.
A project from Rollon and CNC Solutions showcased how cutting-edge robotic automation can meet these challenges head-on. The engineering principles and technologies behind it are directly applicable to many industrial contexts in the UK, especially where payloads are substantial, space is limited, and productivity is key.
A task requiring heavyweight performance
Founded in 2000, CNC Solutions has evolved from enhancing machine tool safety to becoming a leader in custom robotic automation. As an authorised Fanuc system integrator, the company specialises in high-precision applications including machine tending, welding, material removal, and palletising.
During this project, CNC Solutions was tasked with designing a system capable of manipulating 500-pound (approx. 225 kg) pipe flanges using one of the largest industrial robots available: the FANUC® M-900iB/700. With a massive payload capacity, this robot needed to access multiple stations, which presented a significant challenge.
"The heavy payload and large parts meant that we had to ensure structural stability. Furthermore, the solution would need to expand the robot’s operating reach to support the required working area as well," explained Jeffrey Wojtkiewicz, Engineering Manager at CNC Solutions.
The role of Rollon’s RTUf: reliability, flexibility, and strength
To meet this challenge, CNC Solutions turned to a trusted partner: Rollon. Known globally for its linear motion expertise, Rollon supplied its Steel RTUf (Robot Transfer Unit with floor mount), a robust system designed for continuous, high-load industrial use.
The RTUf offered a crucial blend of high load capacity, positioning accuracy, and configurability. Capable of handling large robots and the heavy components they manipulate, the RTUf ensured uninterrupted motion even under intense weight and extended travel requirements.
Crucially, the system's adaptability proved essential. CNC Solutions needed a custom bolt pattern for mounting additional components to the robot saddle.
Cory Roehl, Marketing and Technical Sales Engineer at CNC Solutions, said: “We designed the robotic cell to include additional elements to be bolted to the saddle of the RTUf and then sent the CAD model directly to Rollon so they could include the extra bolt patterns needed, allowing us to attach additional elements securely”.
Precision-engineered performance
The RTUf delivered a travel distance of nearly 13 metres (12,915 mm), supported by two movable saddles, capable of reaching speeds up to 3 m/s with an acceleration of 3 m/s². After installation, CNC Solutions thoroughly tested the solution in a live environment.
This kind of meticulous, high-performance integration is increasingly sought after by manufacturers in UK, particularly in industries such as automotive, food and beverage packing, machinery, and energy, where system downtime is costly and automation must perform reliably under pressure.
This collaboration is just one example of the long-standing relationship between CNC Solutions and Rollon.
In the UK, demand for heavy-duty robotic automation continues to rise, especially as companies strive to modernise their operations, improve workplace safety, and boost productivity. Applications that involve large components, such as those found in shipbuilding, construction equipment, or energy infrastructure, often require bespoke solutions with proven reliability.
Rollon’s RTUs provide a clear benchmark in this space: fully customisable, high-capacity transfer units capable of extending robot functionality without compromising on stability or precision. As integrators and manufacturers increasingly seek out automation solutions that can handle heavy payloads and complex production environments, systems like the one deployed by CNC Solutions offer a compelling roadmap.
“Supporting CNC Solutions on this project was a clear demonstration of what’s possible when strong engineering teams come together with a shared focus on performance and reliability. The application’s payload and precision requirements were substantial, but exactly the kind of challenge our RTU systems are designed for. By collaborating closely during the configuration phase, including customising mounting patterns and ensuring mechanical integration, we were able to deliver a robust linear motion solution that performed seamlessly under demanding real-world conditions. It’s partnerships like these that showcase the adaptability and durability of our technology – we are proud to be a trusted supplier to leading system integrators like CNC Solutions”, said Timothy Prinsloo, Technical Sales Engineer at Rollon.
Future-ready automation
With Rollon’s RTUf, CNC Solutions delivered a custom-engineered, high-performance automation system that overcame the challenges of weight, scale, and precision. This project not only underlines the value of long-term engineering partnerships but also demonstrates how robust linear motion technology can unlock new efficiencies in demanding industrial settings.
For manufacturers in the UK, the message is clear: as operations grow in complexity, collaboration and adaptability will be key.
Print this articleFor more information, please contact:
Rollon UK Ltd
The Works
6 West Street
Olney
Buckinghamshire
MK46 5 HR
Tel: +44 (0) 1234 964024
Email: ukandireland@rollon.com
Web: https://www.rollon.com/
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