Software, Stäubli, and Beckhoff technologies form a new CNC solution

Machine-tool provider CNC Solutions found that traditional teach-in methods, effective for simple pick-and-place tasks, could not handle the complexity of today’s CNC-class workloads. Milling, sanding, and laser or plasma cutting need managing millions of motion points, far beyond the capacity of manual teaching. For these processes, computer-aided manufacturing (CAM) is essential.

Over the decades, CNC Solutions has supported projects that have become increasingly complex — including multi-axis milling, abrasive sanding, and high-speed trimming. For many of these applications today, traditional controller-centric methods are inadequate. For the recent Technology Package, CNC Solutions needed a workflow that began with CAM, simulated the actual cell, and controlled a robot with CNC-level precision and speed.

Stäubli provided precision, repeatability, and sealed construction that resists dust and debris, along with seamless integration of a CNC-style motion layer for trajectory execution. This combination was critical for abrasive applications such as grinding and milling.

The solution is built on three core components. First, ENCY Robot, an offline programming software, calculates toolpaths and simulates the entire cell for industrial robots. Second, a Beckhoff motion controller operates the robot with standard CNC commands, including feeds, modes, and frames. Third, a Stäubli robot executes these paths with the precision and reliability needed for production.

This integrated stack was developed over time. The team gradually refined robot axis motions until the commissioning process matched the consistency of a CNC machine. The result is a standardized solution that integrators can easily implement in their own cells.

CNC Solutions based the offline robot programming layer on ENCY. Rather than spending hours on online programming while the robot is idle, ENCY simulates the entire cell, checks axis limits, avoids singularities, and performs full collision control, converting commissioning time into productive time. The platform offers an all-in-one environment for design, technology setup, toolpath calculation, and simulation, featuring a zero-code digital-twin builder and extensive libraries. In summary, trusted CAM strategies are directly translated into reliable robot instructions.

ENCY was chosen for its broad functionality for both simple two-axis tasks and complex multi-axis cells. Managing code paths and models internally ensures transparent system behavior.

Out-of-the-box processes include milling, grinding, deburring, polishing, blasting (wet/dry), plasma and laser cutting/welding, waterjet cutting, cladding, painting, cleaning, gluing, and more.

With the Technology Package, plug-and-play wiring connects the Stäubli robot to the controller with a single cable, and the package includes predefined processes tailored to each cell. Standard features include CNC-style modes (Auto, Manual, Home), feed overrides, and emergency-stop logic. The system provides process I/O and communication interfaces for plant networks and supports speed control during automatic operation. Manual moves using encoder-wheel controls are also supported.

Recognizing that real cells often deviate from specifications, the package includes features that typically need significant setup time: absolute, TCP, and frame calibration, singularity management, OPC UA connectivity, realtime path adjustments, and tool-wear compensation.

A key metric is how quickly integrators can progress from robot installation to producing the first quality part. By eliminating online robot teaching and providing a CNC-like motion layer, ENCY allows teams to focus on fixtures, tools, and process optimization.

CNC Solutions now commercially offers the Technology Package to integrators as a stable solution that operates such as a machine tool in various shops, industries, and applications.

The core system features a Beckhoff motion cabinet with a CNC-style HMI and handheld pendant, ENCY for offline programming, simulation, and collision or singularity checks, and a streamlined single-cable connection to a Stäubli robot. it’s delivered with predefined processes such as milling, sanding, welding, and laser or plasma cutting, and is engineered for real-world cells with TCP, absolute, and frame calibration, OPC UA integration, realtime path adjustments, and tool-wear compensation. There’s no need to master vendor-specific robot languages, as the stack operates such as a CNC axis group. So, expertise can remain focused on PLCs, safety, fixturing, end-effectors, and process knowledge.

This combination enables higher-value applications such as precision milling, trimming, and sanding, which many integrators previously avoided due to limitations in teach-in methods. Time to first good part is reduced because complex path planning is handled offline. Delivery risk and warranty exposure decrease as more project elements are reused rather than developed from scratch.