The integrated Gantry Loader (GL) automatic overhead robot system on the PUMA TW2100-GL series is a comprehensive, modular automation solution designed to maximize mass production efficiency by minimizing spindle idle time. This is the core feature of this machine series. The 3-axis, servo-driven handling arm delivers exceptionally fast workpiece loading and unloading (Enter → Change → Exit) in just 5.7 seconds (for the GL130 and GL180 models, excluding the top door operating time). 
- Workpiece exchange cycle time (Enter → Change → Exit): Takes just 5.7 seconds (excluding the top door operating time of the machine cabin).
- Axis rapid traverse speeds: X-axis reaches 210 m/min, Y-axis reaches 180 m/min, and Z-axis reaches 55 m/min.
- Payload capacity & workpiece dimension limits:
+ PUMA TW2100-GL130: Maximum workpiece weight of 3.0 kg/part with maximum dimensions of Ø130 x 65 mm.
+ PUMA TW2100W-GL180: Maximum workpiece weight of 3.0 kg/part with maximum dimensions of Ø180 x 80 mm.
- Gantry carriage travels:
+ X-axis: Travel stroke of 1910 mm (for A1 and A2 layouts) or extended up to 3220 mm (for A3 layout).
+ Y-axis: Reaches 560 mm (for the GL130 model) or 610 mm (for the GL180 model).
+ Z-axis: Travel stroke of 200 mm.
◾️ Gantry Layouts and Stocker Configurations
To suit various workshop layouts and customer manufacturing processes, DN Solutions offers three standard layouts:
- A-1 Type: The loading/unloading station and the stocker are centrally located on the left side of the gantry system.
- A-2 Type: The loading/unloading station and the stocker are positioned on the right side of the gantry system.
- A-3 Type: The loading and unloading stations operate independently, with stockers symmetrically placed on both the left and right sides of the gantry.Additionally, advanced gantry configurations are available:
- Twin Gantry Loader (Twin Carriage): Utilizes two independent carriages running on the same gantry beam for parallel handling, further reducing part-exchange times.
- Extended Gantry Loader: Provides longer X, Y, and Z travels to meet specialized workshop requirements.
- Separate Type: Completely separates the left/right machine beds and the gantry system for highly productive, independent machining (e.g., roughing on the left spindle and finishing on the right spindle simultaneously).
◾️Modular Stocker Systems (Stocker Types)Five standard/modular stocker types are available to match the shape and material characteristics of the workpieces:
- Drum Stocker (Rotary Drum): Optimizes shop floor space with a compact footprint while offering large storage capacity and high indexing accuracy.
- Rotary Stocker: Available in Rotary Track or Rotary Round designs.
- Pitch Conveyor: Step-by-step conveyor belt system.
- Push Type / Push Conveyor: Push-driven conveyor mechanism.
- Conveyor Plate / Conveyor: Flat plate conveyor system.
◾️ Intelligent Workpiece Clamping & Turnover Peripherals- Turnover Unit: Provided as standard with the GL system. This unit automatically rotates the workpiece 180 degrees between operations to allow second-side machining after the first side is completed.
- CAM TYPE (SWIVEL) Gripper: An optional cam-type swivel gripper enables smooth, rapid workpiece flipping by the handling arm, minimizing vibration and cycle times.
- Independent Gantry Control Panel: Equipped as standard on the front of the machine. It features an Emergency Stop button, a Manual Pulse Generator (MPG) handwheel for manual axis positioning, and dedicated mode-selection keys, allowing engineers to easily align gripper coordinates.
- Doosan Loader Guidance Software: Visually displayed on the Fanuc i Plus screen, this software enables technicians to easily program gantry motions, monitor gripper/sensor status, and perform rapid troubleshooting.
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📌 Capacity & Machining Envelopes of PUMA TW2100-GL - Chuck Size: 8-inch (Standard).
- Max. Turning Diameter: 130 mm (for PUMA TW2100-GL130) or 180 mm (for PUMA TW2100W-GL180).
- Max. Turning Length: 80 mm.
- Main Spindle Performance:
+ Maximum spindle speed of 4500 r/min (with an optional high-speed Built-in spindle up to 6000 r/min for smaller chuck sizes).
+ Spindle power of 15/11 kW (20/15 Hp) and a peak torque of 127 N·m.
- Turret & Tooling: Equipped with an 8+8 station servo-driven turret (optional 10+10 stations). The PUMA TW2100M-GL (3-axis model) utilizes a high-rigidity BMT45P turret with live-tool capability up to 6000 r/min for superior milling, drilling, and tapping.
- Guide Way Options: Users can configure the foundation with heavy-duty Box guide ways (standard, optimal for heavy cutting) or high-speed LM (Linear Motion) guide ways (optional, optimal for fast, light-duty, and high-precision machining). 
- DN Solutions Fanuc i Plus: A premium CNC system that maximizes productivity, featuring a customized, user-friendly control layout.
- 15-inch iHMI Touchscreen: Includes an intuitive graphical user interface (GUI) and a full QWERTY keyboard for quick, seamless programming and operation.
- Convenience Software Package:
+ EZ-Guide i: A conversational programming solution that automatically generates cutting programs once shape dimensions are entered.
+ Doosan Loader Guidance: Built-in software designed for easy Gantry Loader setup, motion path planning, real-time sensor status monitoring (e.g., swivel and turn-over units), and troubleshooting.
+ EZ Work: Provides hotkeys and utility functions for efficient machine and peripheral device management.
3. Applications in Production
- Fully Automated Mass Production: By eliminating manual work handling through the Gantry Loader and utilizing planning features like the Tool Counter and Work Counter, facilities can run continuous, highly stable unmanned operations.
- Post-Process Measurement Integration: The system seamlessly interfaces with post-process 3D measurement systems (measuring inner/outer diameters or gap differences) to enable Auto Offset (automatic tool compensation), maintaining ultra-tight tolerances over long production runs.
- Flexible Multi-Process Workflows: The dual-spindle configuration allows operators to set up the machine for identical parallel production on both spindles, or sequence them dynamically (e.g., rough machining on the left spindle and finish machining on the right spindle).
4. Machining Materials & Chip Disposal
The PUMA TW2100-GL handles a wide array of raw materials, with optimized chip conveyor setups available depending on the chip characteristics:
- Carbon Steel: Produces long/short chips; best handled by a standard Hinged belt type chip conveyor.
- Cast Iron: Produces fine chips and sludge; highly recommended to use a Magnetic scraper type conveyor.
- Aluminium: Generates thin, lightweight chips; best paired with a Drum filter type conveyor for superior coolant filtration.
5. Actual Machined Products
This turning center is highly optimized for short, disc-like, or ring-shaped workpieces, particularly within the automotive industry:
- Automotive Ring Gears.
- Clutch Boss Components.
- Wheel Hub Bearing Parts / Bearing Races: Proven in actual customer success stories (such as Hwayoung Autotech) to deliver unmatched throughput and precision
Specification Comparison Table: PUMA TW2100 vs. PUMA TW2100-GL | Specifications | PUMA TW2100
(Standard Model) | PUMA TW2100-GL (Gantry Loader Integrated) |
| Chuck size | 8 inch | 8 inch |
| Max. turning diameter | 240 mm | 130 mm (GL130) / 180 mm (GL180) |
| Max. turning length | 128 mm | 80 mm |
| X / Z axis travel | 135 mm / 160 mm | 135 mm / 160 mm |
| X / Z axis rapid traverse | 24 m/min / 24 m/min | 24 m/min / 24 m/min |
| Max. spindle speed | 4500 r/min (6000 r/min Built-in optional) | 4500 r/min (6000 r/min Built-in optional) |
| Max. spindle power (15 min/cont.) | 15/11 kW (Built-in 11/7.5 kW optional) | 15/11 kW (Built-in 11/7.5 kW optional) |
| Max. spindle torque | 127 N·m (Built-in 60 N·m optional) | 127 N·m (Built-in 60 N·m optional) |
| No. of tool stations (Turret) | 8+8 (10+10 optional) | 8+8 (10+10 optional) |
| Automatic Gantry Loader | Not integrated | Standard integration (A1, A2, or A3 type) |
| Gantry payload capacity | N/A | 3.0 kg / part |
| Gantry cycle time (Enter → Change → Exit) | N/A | 5.7 seconds (excluding top door operation) |
| Machine length | 2030 mm (STD) / 2200 mm (WIDE) | 2030 mm (GL130) / 2200 mm (GL180) |
| Machine width | 2098 mm | 2098 mm |
| Machine height | 2278 mm | 2921 mm |
| Machine weight | 4650 kg (4750 kg for [M], [W], [WM] versions) | 5200 kg (GL130) / 5250 kg (GL180) |
| Control System | DN Solutions Fanuc i Plus | DN Solutions Fanuc i Plus |
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