Mike Bacidore is the editor in chief forĀ Control DesignĀ magazine. He is an award-winning columnist, earning a Gold Regional Award and a Silver National Award from the American Society of Business Publication Editors. Email him atĀ [email protected].
How many times have you traveled to Florence, Kentucky, to see the future? I made the trip in October, and it was worth every mile.
Mazak hosted Discover 2015 and demonstrated quite a few of its new technologies at the machine builderās North American manufacturing headquarters.
More than 30 machines, most featuring Mazakās Smooth technology, performed cutting demonstrations of parts via multi-tasking, Hybrid multi-tasking, five-axis, milling and turning techniques.
āThe Smooth control is the next generation in a long line of Mazak controls,ā said Mike Kerscher, product manager. āMazakās SmoothX is the seventh-generation Mazatrol CNC system, with a mix of improvements in hardware, software and operability.ā
SmoothX is a five-axis control matched to machine performance. āWe're trying to supply as much control as you need for your operation,ā explained Kerscher. āSmoothX is the world's fastest CNC, with a quick programming screen and intuitive HMI for five-axis virtual machining, variable acceleration control, corner control and machining configuration.ā
Variable acceleration control is a new function. It calculates optimal acceleration for each block, or each combination of moving axes. It ensures maximum capability of each axis and reduces cycle time while maintaining high accuracy.
āGenerally, low acceleration is applied for a rotary axis with a gear mechanism,ā explained Kerscher. āThe low acceleration used to be applied also for linear axes on conventional models because only one acceleration setting was allowed on the machine. Variable acceleration control allows individual acceleration settings for each axis. Smooth corner control is a new function that reduces unnecessary acceleration and deceleration at corners and curves, makes cornering motion smoother, shortens cycle time and accomplishes a smooth surface finish in keeping high accuracy. This means you accelerate and decelerate a lot faster.ā
Smooth machining and tuning are selectable on the configuration screen. āThe customer can adjust the tuning and store it as his preferred tuning on the screen,ā said Kerscher. āTo make a process smoother, you can select the mix of smoothness, speed and accuracy. Once you tweak it, you can assign an M code to it and call it up again in the program. It gives the end user the ability to change parameters, which you couldn't do before.ā
The big difference is the Windows 8 tablet-type operating system with touch control. āIntuitive operation is available by touch operation, just like smart phones or tablets,ā said Kerscher.
Also read:Ā Mazak improves OEE with MTConnect
The screen keyboard automatically appears when itās needed. The HMI also provides undo/redo for programming and data setting such as tool data and parameters. āBut it doesn't work after the cut,ā joked Kerscher.
More often, one operator is running multiple machines. The home screen allows for monitoring of up to five Smooth-controlled machines on the shop floor. āYou just click on it and enter the IP address to set it up,ā said Kerscher. āIt doesn't matter if it's wired or wireless.ā
iSmart Factory
As part of Discover, Mazak also offered tours of its renovated manufacturing facilityā536,000 sq ft of the 800,000-sq-ft campus. While investing $30 million in the campus in 2014, Mazak implemented its iSmart Factory, which brings connectivity to on-demand operations.Ā Mazak also discussed how manufacturers can turn data into real-time actionable intelligence using communications protocols such as MTConnect.
The Integrex i-400AM, Mazakās Hybrid multi-tasking machine, is designed to integrate laser cladding with five-axis milling and turning capabilities and is outfitted with the Mazatrol SmoothX CNC control.
Mazakās Smart Box includes MTConnect. āIt's a product to allow you to connect to a machine tool,ā explained Kerscher. āWe've had the ability to plug into the machine control for years, but IT guys don't like that. SmartBox is a collaboration with Cisco.ā
To allay the fears and resistance of the IT community to have the Internet of Things, SmartBox is a professional outlet that provides a professional method to connect. āIt's secure, so itās IT-friendly,ā said Kerscher. āThe IT guy sees a Cisco switch, so he's comfortable. He can set up firewalls. We can collect data and analyze it locally.ā Plus, SmartBox is expandable, so machines and sensors can be added.
āWeāre moving forward into the IIoT or Industry 4.0, that next revolution in industry, where we'll start dealing with data,ā explained Kerscher. āOn the Smooth suite of controls, Mazak SmartLink is the ability to view and interact with the machine control from a mobile device. SmartLink provides access to real-time monitoring, control and management. We can look at programs, tool management and machine monitoring. And we can make changes.ā Of course, a cycle-start cannot be initiated remotely.
Additive manufacturing
No view of the future would be complete without a dab of additive manufacturing. Mazakās Integrex i-400AM is changing the way engineers and designers view product development.
Integrex i-400AM, Mazakās Hybrid multi-tasking machine, made its North American debut at Discover 2015. Designed to integrate laser cladding with five-axis milling and turning capabilities, the machine is outfitted with the Mazatrol SmoothX CNC control.