Blog Archives - Whitehouse Machine Tools

Interconnected technologies in CNC machining

wmtcnc — Thu, 31 Oct 2024 15:08:05 +0000

Manufacturers embrace modularity with CubeBOX automation system

Bill Gates believes that Generative artificial intelligence (GenAI) has potential “to change the world in ways that we can’t even imagine,” highlighting its potential to innovate and enhance productivity across various sectors. For manufacturers striving to remain competitive and meet the evolving demands of the metalworking industry, embracing such technologies will be crucial. Here, Hakan Aydogdu, general manager of CNC automation system manufacturer, Tezmaksan Robot Technologies, explains how embracing modular and adaptable technologies, complemented by GenAI, can help manufacturers improve efficiency, reduce costs and stay competitive.

The landscape of CNC machining stands on the brink of significant change, largely driven by GenAI. In his blog, The age of AI has begun, Gates notes this technology could address major global issues such as climate change and disease, with implications for manufacturing that extend beyond mere operational improvements.

Recent research by McKinsey & Company indicates a rapid adoption of GenAI, with 65 per cent of organisations integrating it into their operations—almost double the rate from the previous year. This trend is particularly notable in product development and IT, sectors integral to manufacturing. The same study reports that GenAI is proving valuable for optimising supply chain operations and inventory management, leading to revenue increases of over five per cent for many manufacturers through improved demand forecasting, automated inventory tracking and streamlined logistics.

Challenges in integration

Nevertheless, the integration of GenAI into CNC machining presents challenges. One major issue is synchronising advanced AI systems with existing machinery, which often necessitates costly modifications to infrastructure. IBM Research highlights that overcoming these compatibility issues can be both time-consuming and expensive.

Smaller manufacturers face additional hurdles due to the high costs associated with advanced automation and AI technologies. Ongoing investments to keep pace with rapid technological advancements can strain financial resources. The July 2023 AI Pulse Survey by Forrester notes that many organisations are struggling with the financial pressures of continuous technology upgrades, compounded by the need for frequent maintenance and system customisation.

Modular and adaptable solutions

To address these challenges, modular and adaptable technologies are emerging as viable solutions. These systems offer greater flexibility and ease of integration with existing setups. They can be tailored to specific needs and scaled as required, minimising disruption during technology implementation.

In a smart factory, modular and adaptable technologies facilitate flexible production lines. Robots and machinery are designed to be modular, so only specific components—such as tooling or programming modules—need adjustment when introducing a new product line. This flexibility allows for quick transitions between different production runs with minimal downtime or additional costs.

Adaptable Internet of Things (IoT) technologies play a crucial role in modern manufacturing. These systems use sensors, data analytics and connectivity to provide real-time data from various parts of the production line. IoT devices can be reprogrammed or recalibrated to track new metrics or communicate with different devices as production needs evolve. For instance, if a factory begins manufacturing a new product, sensors can be updated to monitor different quality control criteria without overhauling the entire system.

Simplifying implementation

However, integrating modular and adaptable technologies with existing systems remains complex. Many organisations still use legacy infrastructures not designed for modern, flexible solutions, making the transition both time-consuming and costly. Customising and scaling these technologies often requires specialised knowledge, creating potential bottlenecks during implementation. Ensuring seamless communication between new modules and older systems, while maintaining efficiency and minimising disruption, is a significant challenge.

Here, generative AI plays a vital role. IBM Research points out that GenAI’s ability to automate code generation and simplify complex processes can help streamline the integration of new technologies. This capability reduces the need for extensive manual programming and system adjustments, thus enhancing overall operational efficiency.

Consider the CubeBOX, a compact, adaptable automation system designed to streamline the operation of CNC machines. This system enhances productivity by automating loading and unloading processes, allowing the machines to run continuously around the clock without human intervention.

The CubeBOX features a cost-effective, plug-and-play design that integrates easily with various CNC machines and robot brands. The system’s ability to handle pallet changes while the machine operates and its user-friendly software—converting CAD designs into machine instructions—demonstrate its effectiveness in increasing productivity, particularly during night shifts.

Increasingly competitive

The system’s modular design allows for easy adaptation and movement between machines, making it a versatile solution for different production needs. It is compatible with a range of CNC machines, including lathes, machining centres and grinding machines and is priced 20 per cent lower than comparable solutions.

Complementing this system is ROBOCAM, an intelligent automation software that simplifies programming. ROBOCAM enables operators to upload product drawings, which are then converted into commands for the robot. This user-friendly software reduces the need for extensive programming knowledge and accelerates the implementation process, addressing a common challenge in automation adoption.

Imagine a mid-sized manufacturing company that produces high-precision components for the aerospace industry. Traditionally reliant on manual CNC machine tending, the company faces high labour costs and downtime, particularly during night shifts. By implementing this robotic automation system, the company could run its CNC machines continuously, increasing night shift efficiency by 50 per cent and reducing lead times. The system’s compatibility with various machines allows for seamless integration with minimal downtime. ROBOCAM further enhances efficiency by simplifying programming, allowing for quick adjustments to new product designs and production runs.

As the industry adapts to these transformative technologies, the future of CNC machining is set to be shaped by innovations such as this robotic automation system and ROBOCAM. By embracing these advancements, manufacturers can enhance efficiency, reduce costs and position themselves for sustained success in an increasingly competitive landscape.

To learn more about Tezmaksan’s CubeBOX automation systems, visit the website.

The post Interconnected technologies in CNC machining appeared first on Whitehouse Machine Tools.

What Is Mill/Turn Machining?

wmtcnc — Fri, 06 Jan 2023 15:10:08 +0000

From medical implants to aerospace components, extremely precise parts are the key to keeping some of most critical aspects of our modern world running smoothly.

Manufacturing these small, complex parts efficiently, and within demanding tolerances, requires the right state-of-the-art equipment paired with the engineering skills to exploit it.

Increasingly such parts are manufactured in a single set-up using mill/turn machinery.

This blog is intending to explain how a mill/turn works, how a mill/turn is used in high precision parts manufacturing, and the many benefits of the mill/turn’s combined functionality.

What Is a Mill/Turn Machine?

A mill/turn machine is a hybrid CNC (computer numerical control) machine that combines both milling (tool rotating) and turning (workpiece rotating) functionalities into one fast, powerful, and flexible machine that can complete complex operations faster and with greater accuracy than traditional machining technologies.

While other machines perform a single function, mill/turn machines can accomplish up to four operations at the same time.

Brother M200Xd1 - example of Mill/Turn machinery

Benefits of Mill/Turn Machines

Mill/turn machines are a newer technology, and because of that, they are less common in machine shops compared to traditional milling and turning machines. However, combined mill/turn technology enables a wide variety of benefits compared to traditional machines, including:

Ability to machine more complex parts

Mill/turn machines are able to create more complex and intricate parts without needing to transfer the part from one machine to another. This opens a world of possibilities. Use of this equipment can enable UK manufacturers to take on more complex and higher precision jobs and produce the parts more competitively. Parts that many would perhaps have previously either turned away, or been unable to produce efficiently.

Faster operations

Because a mill/turn can complete 4 operations at the same time, the total time needed to create each part is significantly reduced. In addition to machining the parts faster, mill/turns can also be set up more quickly than other machines. Most of this time savings is because raw material only needs to be set up once to perform all the different operations, without requiring the part to be adjusted or moved to another machine after each operation.

Higher accuracy

Automation of menial tasks

Since most mill/turn machines are newer, they offer more built-in automation than traditional machining equipment. Tasks like loading material, probing, and removing parts are done automatically, freeing up the machinist’s time to do other more interesting and value-added activities.

Using mill/turn machines to combine operations, means less machinery – or less floor-space. Fewer machines in turn means reduced operators. It also means less power and compressed air is consumed. All of these reductions combine to deliver cost savings and improve profitability.

As the advances in user-friendly CAD/CAM packages with Mill/turn platforms and post-processors, mean it is also much more accessible and no-longer just the preserve of large tier one specialists.

And with more machine tool manufacturers beginning to produce Mill/turn technology so it becomes more commonplace and more affordable than you might think.

The benefits of this technology is increasingly being harnessed by forward thinking sub-contractors, looking for a competitive edge.

Resources...

Mill/Turn Videos

Hemlock Feedio Case Study

The post What Is Mill/Turn Machining? appeared first on Whitehouse Machine Tools.

Can Machine Tools be Energy Efficient?

wmtcnc — Wed, 07 Jul 2021 13:39:03 +0000

Brother Industries: Cutting Out Waste

The latest generation of SPEEDIO machines from Brother Industries in Nagoya have been designed to reduce energy consumption as well as cycle-times.

Helping the environment as well as your energy bills

This range of high-speed vertical machining centres utilise a range of measures to minimise the amount of energy consumed when compared to previous generations of Brother machines, or competitors’ machinery.

Reducing the energy required

Initial reductions are achieved through a series of enhancements, such as specifying a CPU that consumes less power, reducing the number of fans in the NC cabinet, using an LCD backlight and deploying an automatic power-off function on the lights.

Further reductions are delivered through the use of latest technology Coolant Pumps, Servo Controls and Interior LED lights, all developed specifically to consume less power.

Less Loss

As well as reducing the energy consumed, Brother’s philosophy of “low-mass, high acceleration” or “lightweight, low inertia” design, also means that the amount of energy lost due to sliding is minimised.

Not just Power, Air too

The environmental savings are not limited to electricity. Focus has been placed too on air-saving technologies. Measures such as optimised air-blast timings and an extremely air-tight air purge structure, help achieve reductions in the amount of compressed air needed.

Power Regeneration

More significant, savings have been accomplished through the use of Power Regeneration Technology – based on the principles of KERS from Formula 1.

Where other machines emit the power generated through resistance when the motor stops as “heat”, the new generation of SPEEDIO machines harness this power, converting it to electric current, for re-use.

On certain power intensive cycles, such as those that require multiple spindle start/stops to/from high speed (for instance tapping), this power regeneration capability can result in dramatic reductions.

For example, when compared to a BT40 machine, a programme consisting of mainly drilling and tapping uses 60% power when run on the new SPEEDIO W1000Xd1. Likewise, a programme made-up of mainly milling and end-milling uses 30% less power.

Increased responsiveness decreases run times

Similarly, the use of IPM technology (interior permanent magnet) on the high efficiency Spindle Motor improves responsiveness when compared to the conventional induction motors used on other machine tools.

This enhanced responsiveness results in reductions to cycle times which in turn delivers further reductions in power consumption.

Cycle times and therefore energy savings are further reduced by other features on the new SPEEDIO machines, such as simultaneously performing Tool-Change and positioning XYZ axes.

So, in short: Quicker Cycle Times = Higher Productivity = Less Power required to machine each part

BT30 Technology

Brother’s long-established belief in the efficiency of BT30 Spindle technology has also been proven deliver benefits in a similar way, with BT40 machines shown to require up to 4 times the power to produce the same components.

View the Savings

So committed are Brother to making their latest machines “Earth Friendly”, their Engineers have even included an App on the new D00 control that enables users to monitor exactly what power is being consumed.

End Result

The combined effect of all of these measures is that the latest SPEEDIO models are better for the environment, better for your productivity and better for your profitability.

The post Can Machine Tools be Energy Efficient? appeared first on Whitehouse Machine Tools.

Are the benefits of Automation only for Mass Market Manufacturers?

wmtcnc — Wed, 09 Mar 2022 11:33:40 +0000

The increasing demand for automation solutions in the UK manufacturing engineering sector has boosted the requirement for multi skilled engineers. These engineers must be capable of programming CNC machine tools combined with the knowledge to integrate industrial and collaborative robot systems.

When considering the integration of robotic solutions to CNC machine tools, a holistic approach is needed. There are many work-holding and tooling decisions to be made, from coBots to plug and play Plug & Play solutions now opening up Automation solutions to evening smaller manufacturers.

Whilst the UK manufacturing sector has not traditionally invested heavily in automation, compared to Italy and Germany, recent changes in world standing and economic direction is driving smaller businesses to embrace higher efficiency machines tools.

What are the Challenges and questions facing our UK customers in manufacturing of component parts?

How to reduce or eliminate set up time?
How to increase productivity?
How to increase machine utilisation?
How to reduce labour while increasing productivity?
How to be more competitive?
How to get better utilisation of floor space?

Machine Tool manufacturers now provide answers to some of these questions with technology offering the following solutions:

Multi-operational machining in one set up
Multi-face machining in one set up
Larger tool changers to minimise tool set-ups from part to part.

But where the bottle neck can be is in the feeding of the machine tool.

One growing solution is automation of this process providing

Increased utilisation of the machine tool
Providing unmanned running
Reducing labour
Increasing productivity and profitability

Automation is no longer for high volume component part manufacturing.

The technology and solutions provided today offer a great deal of flexibility and useability.

Features such as:

Flexible, easy to set grippers
Vision camera that is specifically designed for robot guidance and has a very simple and intuitive workpiece teach-in process. No requirement for component templates or trays
Simple part infeed and outfeed conveyors
Easy manual driven programming

WMT have now provided many installations demonstrating the benefits as pointed out above increasing our customers productivity, making them more competitive on a global market and more importantly more profitable

The post Are the benefits of Automation only for Mass Market Manufacturers? appeared first on Whitehouse Machine Tools.