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TECH INNOVATION
4 Reasons Your
Machine Shop Needs
Energy-Efficient
CNC Machines
oday’s manufacturers experience workflow. Then, they can become aware plus get warnings about possible
ongoing pressure to reduce of problems earlier and tackle them impending machine failures. Achieving
Ttheir resource usage. There are before they cause major disruptions or better visibility is critical because having
many ways to do that, but one of the slowdowns. energy-efficient CNC machines is only
most practical is to explore ways to cut Some such innovations for machine one component to consider.
energy usage used by tools such as CNC shops show performance data for People can also save energy by
machines. Here are some compelling each workpiece, including energy improving their processes. Doing
reasons to consider investing in energy- consumption information. Additionally, seemingly simple things like turning
efficient CNC machines. connected machines often have auxiliary tools on and off so that they’re
condition-monitoring aspects. They only active when needed saves energy.
1. You’ll Often Get Better Overall indicate the friction values for axles It’s also possible to lock and disconnect
Visibility and spindles, the milling housing’s motors from power sources when they’re
Many energy-efficient CNC machines temperature and the vibration statistics not in use.
have smart connectivity features for specific bearings. Getting more visibility into the overall
that make it easy for users and shop When you can see real-time statistics, process allows people to look at more-
supervisors to track trends that as well as patterns over time, it’s easier granular aspects and feel more confident
could maximize or hinder the overall to pursue energy-saving measures, about making strategic changes. Then,
48 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
they’re more likely to notice better energy-saving CNC machines as part of a Some CNC machines have similar
energy efficiency and other gains. larger effort to get their operations ready features to reduce energy consumption.
for the future, allowing their organization For example, the energy used to slow
2. Energy-Efficient CNC Machines to remain resilient and competitive. Such down one motor could help accelerate
Can Increase Productivity all-encompassing upgrades typically another. Such an approach offers an
An energy-efficient machine can have require understanding and accurately alternative to friction clutches and brakes.
numerous upgrades that collectively calculating a company’s energy needs. Before a machine shop leader invests
enhance the workflow. Then, it’s High-quality transformers are often in a CNC machine with regenerative
possible to improve several metrics essential for keeping things running braking capabilities, they should consider
simultaneously, both related and smoothly in the manufacturing sector tracking the amount of energy currently
unrelated to energy usage. and numerous other industries. However, used. Then, it’ll be easier to gauge the
Consider the case of recently released selecting the wrong transformer size impact the regenerative braking has on
machines from Brother. One has a can ruin equipment and cause additional energy consumption and overall process
15-inch screen with touch sensitivity, unwanted outcomes. Knowing a improvement.
enabling better productivity compared to company’s current energy needs enables Having that information also makes it
earlier CNC machines from the company. purchasing the right transformer and easier to engage in communications with
On the energy-efficiency side of things, having expectations met or exceeded. machine tool representatives to give them
the new machines have hybrid drive When people decide to focus on an idea of a company’s current process
motors that allow the low-inertia spindle energy efficiency when upgrading their and where room for improvement exists.
motor to accelerate and decelerate CNC machines, they may also make other Since getting better energy efficiency
more efficiently. That change has choices that optimize production and get is such an ongoing concern, company
caused a 25% reduction in tool-to-tool a machine shop ready for the future. For representatives know how to describe
time. Similarly, the cut-to-cut time has example, some robotics providers sell features so that potential customers
gone down from 1.4 to 1.2 seconds. solutions that allow using collaborative quickly recognize the advantages.
That improvement allows for a 3-9% robots during parts of the CNC machining
cycle time reduction, depending on the process. Representatives from these Are You Ready to Buy Energy-
complexity and size of the workpiece. companies sell options that people can Efficient CNC Machines?
Some of the new machines from set up in a few hours at most. They’re Purchasing an energy-saving CNC
Brother are also specially engineered to ideal for purchasers with little or no machine is not a decision to reach in
reduce idle time. Besides saving energy, experience with robots. haste. You’ll feel more confident about
the cut in idle time helps machine workers Many national and state leaders are taking that step after thinking about the
make the most of their efforts on every incentivizing manufacturers to make specific goals you want to achieve and
shift. changes to support sustainability. which barriers prevent such outcomes
Learning about the features of energy- Achieving better energy efficiency is only now.
efficient CNC machines is an excellent one part of that, but it’s certainly worth Remember, too, that the maximum
way to make better buying decisions. considering. India and Canada are two payoffs associated with new equipment
Today’s machine tool manufacturers places where government leaders have almost never happen immediately. It takes
understand that saving energy is often a previously offered rebate programs for time for people to get acquainted with
priority of today’s product users, but it’s people who decide to purchase energy- new features and operating modes.
not their only concern. Keeping track of efficient CNC machines. Finally, when people opt to get energy-
the specific benefits a new CNC machine efficient equipment, they can typically
offers after utilization begins is also a 4. Regenerative Braking Features treat it as a long-term investment. Most
smart way to justify future investments Can Reduce Energy Expenditure modern CNC machines are made for
into upgrades. Electric and hybrid vehicles often have reliability and longevity, enabling them
regenerative braking technology. It works to offer years of dependable usage. Even
3. Energy-Efficient CNC Machines by turning the kinetic energy associated if that benefit doesn’t directly translate
Can Support a Future-Oriented with applying a brake into electrical to better energy efficiency, it can make
Mindset energy. That process reduces the amount people more eager to purchase and look
A machine shop owner may purchase of energy needed to power the machine. forward to long-term advantages.
www.mtwmag.com AUGUST 2022 MACHINE TOOLS WORLD 49
TECH INNOVATION
Innovative capacitive sensors
for industrial use
Achieving high precision with non-contact measurement
Capacitive displacement sensors are still deemed to be primarily suited to clean, dry environments. However,
in the form of industry-optimized models such as those designed by Micro-Epsilon, capacitive sensors achieve
peak performances in harsh industrial applications. They also measure with the highest precision down to
sub-micrometer accuracy in industrial environments. With temperature resistance, robustness and flexibility,
capacitive sensors can also be used in environments where fluctuating temperatures or magnetic fields occur.
apacitive displacement sensors of an electrical property described as C = ϵ × Ad
mainly determine changes in capacity. This is a body’s or conductor C = Capacity
Cdisplacement and position of arrangement’s ability to store electrical ϵ = Dielectric constant
conductive objects. Here, Micro-Epsilon charge. Capacitive sensors from Micro- A = Surface of capacitor plates
applies its expertise in the development Epsilon are based on the principle of the d = Distance between capacitor plates
of innovative capaNCDT sensors from ideal plate capacitor. The electric field is
50 years of company history. This is how only located between the two conductive Sensor designs for different fields
these sensors, which originally were objects in the active measuring range, i.e. of application
assigned to clean environments, have between the sensor and the conductive Capacitive capaNCDT sensors are
become stable, high precision measuring measurement object. The sensor electrode available in different models. The
systems for industrial applications. is fed with alternating current of constant cylindrical version is the most common
frequency and amplitude which is why design. New, cylindrical displacement
How does the capacitive the amplitude of the resulting voltage is sensors from Micro-Epsilon have a
displacement sensor work? proportional to the distance of the two mounting thread and can be easily
Capacitive sensors measure changes objects. screwed in or fixed in place using a nut.
50 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
In addition to the cylindrical design, surface. The protective field around the particularly narrow installation spaces. The
flat sensors are available which require measurement electrode prevents this spiral sheathing for the cables used offers
significantly less installation space. The field from spreading over other close additional protection against damage.
PCB model of capacitive sensors is ideally conductive objects or other areas of The PCB sensors of the CFS series cover
suited to installation in narrow, confined the target. It inhibits other objects from measuring ranges from 2 mm to 6 mm
spaces. influencing the measurement. This triaxial and achieve a linearity of 4 µm.
Capacitive sensors cover measuring design makes the sensors more robust
ranges of 50 µm to 10 mm and and considerably more accurate. Linearity Insensitive to magnetic fields: air
are therefore suitable for multiple is significantly improved and interferences gap measurement in large electric
measurement tasks. The sensors are of the measuring field are reliably motors
either equipped with plug-in connection prevented. In addition, these sensors can The advantages of industry-optimized
or integrated cable. Different housing be flush mounted in conductive materials sensors become evident, among other
materials and manufacturing technologies without generating a measuring error. things, with large electric motors such
are used for sensor construction. As as those found in rock grinding mills
well as the standard stainless steel/Invar Patented miniature plug for cement production or for mining.
design, sensors made from titanium, which Micro-Epsilon also provides a suitable The runout of these systems must be
are suitable for measurements in vacuums, solution for particularly restricted permanently monitored. With diameters
are also available. installation situations. A patented of more than 10 m, the motors are badly
miniature triaxial connector is used damaged when the rotor touches the
More precision with triaxial design together with the PCB sensors that are stator. This is why the air gap, i.e. the
Unlike conventional capacitive sensors, only 14 mm to 25 mm thick. Cable, sensor distance between the rotor and stator, is
sensors from Micro-Epsilon do not appear and connector are almost the same size monitored using capacitive displacement
as with coaxial but as triaxial designs. here, which means in simple terms: where sensors. Due to the triaxial design and the
This means that the capacitor is not the cable fits through, the connector also non-ferromagnetic materials used such as
simply surrounded by a housing but, in fits through. There is no need for time- titanium or stainless steel, the changing
addition, an extra-fed guard ring is located consuming drilling of large holes. At only magnetic fields have no influence on
between the capacitor and the housing, 3.6 mm, the connector is about three times the measurement result. Due to the
which generates an electric field. This smaller than conventional connectors. non-contact measuring principle, there
creates a homogeneous field between the This greatly simplifies integration of the is no physical impact onto the sensor or
measurement electrode and the object sensor in machines and systems with measurement object which, provides long-
www.mtwmag.com AUGUST 2022 MACHINE TOOLS WORLD 51
TECH INNOVATION
distance, e.g., on walls, in bore holes or
even very deep drill holes. Capacitive
thread sensors can also be mounted on
thin walls using two lock nuts on both the
inside and outside. Due to their integrated
plug-in connection, thread sensors are
easy to install. This prevents the cable
from twisting. First, the sensors are
screwed in and only afterwards connected
with the cable via the integrated plug-in
connection.
Temperature-stable results
term stability. Different sensor designs, In industrial environments, the
including flat sensors, also enable easy temperature often fluctuates very strongly.
installation in these harsh environments, Materials expand with high temperatures
which only offers a small mounting space and contract with lower temperatures.
requiring sensors with a max. height of 2.5 This is why the distance between sensor
mm. Another challenge is the large cable and measurement object can change
length which should usually be about 8 m. too. In areas with strongly fluctuating
temperatures, capacitive sensors from
Modifications possible at any time Micro-Epsilon offer, in the range from
In addition to the standard sensors, Micro- -270 °C to +200 °C, extremely high
Epsilon offers the possibility to modify temperature stability of 5 ppm. Long-term
sensors and controllers according to the stability is ±0.002 %FSO/month. For much
customer’s requirements, among other higher temperature ranges, special sensor
things, with respect to cable length, sensor designs with ceramics can be provided.
design or modified measuring ranges. In Extremely temperature-stable and
areas where sensors are to a great extent robust sensors are required with non-
exposed to shocks, thread sensors offer contact detection of Disc Thickness determines deviations well below 1µm
an ideal installation option. These are Variation of automotive brake discs. In in a test bench at room temperature
firmly screwed to the respective machine order to achieve maximum efficiency of and also during road tests when the
and prevent the sensor from slipping the braking system, the disc must have an brake disc reaches temperatures of
due to strong vibrations. This is how the even, consistent thickness. Unevenness, 600 degrees Celsius. For brake disc
measurement results remain precise on runout or abrasion on the friction surface thickness measurements, Micro-Epsilon
a long-term basis even in challenging of the disc causes the brake pads to lose has designed an innovative 4-channel
environments. They are specially designed contact with the rotating disc, which in sensor. Its robust construction makes
for machine building applications where turn reduces the braking effect. Providing the sensor perfectly suitable for harsh
the sensors must be mounted at a defined high resolution, the capaNCDT DTV ambient conditions from production
monitoring and quality control via test
benches to on-road vehicle purposes.
In its compact housing, four capacitive
sensors detect the measurement values
with each operating in standalone mode.
A special ceramic substrate protects the
sensors from mechanical and thermal
loads, providing high temperature stability.
In order to enable accurate measurements
with simplified mounting, the sensors are
52 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
Micro-Epsilon for displacement, distance
and position measurement.
available as mirror-inverted arrangements measurement results by deformation of
that can be mounted on opposite sides the measuring platform itself, the use of Use in ultra-high vacuum: electron
of the brake disc. Combined with the extremely thermally stable sensors and accelerator
capaNCDT 6220 controller, the four sensor ULE (ultra-low expansion) materials such Also in ultra-high vacuum, capaNCDT
channels can be processed synchronously as Clearceram and Zerodur are necessary. sensors perform with high precision.
with dynamic measurements up to This is a glass ceramic that has extremely With its project “bERLinPro”, Helmholtz
5kHz and digital outputs via Ethernet or low thermal expansion and length Zentrum Berlin [HZB] strives to develop
EtherCAT or as analog signal. stability. One of the measuring tasks is a new technological basis for an “Energy
to determine the thermal expansion of Recovery Linac” (linear accelerator with
Space research: capacitive star sensor carriers. Star sensors are energy recovery) in order to further
sensors measure under extreme optical measuring instruments based on develop accelerator technologies.
temperature conditions CCD elements or other optical sensors. Helmholtz Zentrum Berlin relies for
The extraordinary temperature stability of Their task is to search and determine this purpose on Micro-Epsilon’s precise
sensors is demonstrated by measurement the direction of bright celestial bodies. measuring technology. A photo cathode
tasks for space research. In areas away For aerospace, star sensors are of the in a superconductive high-frequency
from the sun, the lowest temperatures utmost importance. They are necessary electron gun is used to optimize the source
are down to -271°C, which is just above for determining the attitude and attitude of the electron bunches that are to be
absolute zero and therefore in the control. For example, satellites also use the accelerated. During further acceleration,
cryogenic temperature range. However, stars in the sky to position themselves in the electron bunches thereby generated
in trajectories where the components space. Star sensors must therefore provide remain more compact than bunches from
face the sun, they become extremely hot micrometer-accurate measurement results other sources. This allows them to be
with temperatures rising rapidly to more in order to derive from them the exact used for achieving higher-quality X-rays,
than 200°C. In addition, rather than the positioning of satellites in space. Therefore, among other things. The electron source in
Earth’s atmosphere, vacuum prevails. the supports on which star sensors are the bERLinPro project is aligned by using
All components that are used in space mounted must not be subjected to any three capacitive flat sensors together with
travel missions must withstand these thermal deformation. The behavior of the a DT6220 controller. In the process, the
extreme conditions. For example, material material used is therefore tested using tilting and change of the holder’s position
should not expand thermally, should be high precision capacitive sensors from during cooling from room temperature to
as free from gas emissions as possible,
and be resistant to radiation. In terms
of metrology, three factors are crucial:
robustness, reliability and long service life.
KRP Mechatec GmbH is an engineering
services company that has specialized
in aerospace structural design, analysis
and testing, as well as fusion research.
In cooperation with Micro-Epsilon, a
measuring platform for high precision
thermal deformation measurement
of space components has been co-
developed.
The experimental verification of
thermo-elastically stable structures
requires a measurement platform with
much higher thermal stability than can
be demonstrated by the components
to be investigated. In order not to falsify
www.mtwmag.com AUGUST 2022 MACHINE TOOLS WORLD 53
TECH INNOVATION
experiments under radioactive radiation,
only the sensor is mounted within the
radiation area. The other components
such as cable and controller are outside,
which is why the system is easy to
maintain. Therefore, all components are
interchangeable. Particularly with extreme
radiation-affected applications such as the
particle accelerator, it is possible to place
the control and evaluation unit at safe
distance from 6-8m due to its long cable
length.
Measuring systems for the industry
In addition to a wide, industry-optimized
sensor range, Micro-Epsilon offers
special systems which were designed for
2 Kelvin (-271 °C) is monitored. Micro- a change in height is precisely detected industrial requirements. The capaNCDT
Epsilon’s DT6220 measuring system via the water level. For the measurements, 61x0/IP capacitive displacement
was selected because of the combination several systems are joined together via measuring system is suitable for inline
of prevailing ambient conditions (very hoses. quality assurance of production processes,
low temperatures in the physical low The water level in the “water pot” levels and for control of plant and machinery.
limit range, ultra-high vacuum, x-ray out after a certain time. This water level Protected to IP68, this measuring
bremsstrahlung (braking radiation) and indicates if both concrete bases are on system is therefore suitable for many
weak radio-frequency interference) and the same horizontal plane. Due to gravity, industrial measurement tasks. Fluctuating
requirements for sensor type, temperature the water levels out in the hose so that temperatures and magnetic fields are
and long-term stability. Thanks to the the water level is the same in all CHLS4 no match for this capacitive system.
system’s modular design, all three systems - provided that they are all on It is specially designed for industrial
measuring locations can be captured with the same plane. If the height of one of measurement tasks where high precision
just one controller. the concrete pillars changes due to earth is required. It detects parameters such
movement, the sensor detects this with as displacement, distance, deflection,
Sensor design for measurements in high precision. The ambient conditions are expansion, and deformation of conductive
the particle accelerator a particular challenge in this measurement targets.
Capacitive sensors from Micro-Epsilon are task. The sensor is in this case embedded The capaNCDT 61x0/IP includes a
used in a special design as the Hydrostatic in a protection housing which is equipped sensor, sensor cable and controller.
Leveling System CHLS4 in particle with a flat, heated sensor element. This Calibrated at the factory, the system is
accelerators. The altitude of the measuring is always a few degrees warmer than immediately ready for use with no on site
stations in the kilometer-long pipe system its environment and therefore stays dry. calibration necessary. Even after replacing
therefore must be inspected continuously, The height of the water level can be the sensors, no recalibration is required.
while achieving an accuracy in the monitored through the sensor element and Data output is via current, voltage or digital
submicrometer range in order to ensure a precise distance measurement against RS485 interface. Its aluminum die-cast
high functional safety and efficiency with the water surface can be carried out. With housing protects the controller from dust
the particle collision. The concrete pillars
have been constructed at a distance of
about six to eight meters. The CHLS4 is at
their base, with one sensor per concrete
base respectively. These sensors are
interconnected with a hose system. Similar
to the conventional water level principle,
54 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
and humidity. As the sensor cable is
extremely robust, it provides resistance to
treading and high temperatures. The cable
length is designed for large distances
up to 8 meters. More than 15 different
sensor models are available for different
measurement tasks. Board sensors,
cylindrical sensors and models with thread
are the three basic sensor types from
which the customer can choose depending
on the respective installation scenario.
The sensor can be replaced easily. All
capacitive sensors from Micro-Epsilon are
compatible with all controllers. Complex
sensor calibration is not necessary.
Conclusion
Almost no other system is able to detect
linearity deviations up to 0.005% and
better across the whole measuring range.
Despite comparatively high conduction
capacities up to 1nF (1x10e-9 F), the
measurement capacity can be resolved to
approx. 0.25aF (0.25*10e-18 F), a relation
of 1:4,000,000,000. This is achieved
with the corresponding subtleties in
the high quality components, from the
sensor via the sensor connection cable
to the controller. Micro-Epsilon capacitive are no integrated components that could from semiconductor industry via air
sensors are principally passive. Therefore, reduce the service life. Another strength gap measurement of large motors to
there are no electronic components that is the combination variety. Each capacitive deformation measurement of brake
are sensitive to temperature which leads sensor can be operated with any Micro- discs or positioning of machines
to high long-term stability and extreme Epsilon controller without requiring any • The perfect sensor for each
precision. Capacitive sensors are often complex calibration. The various interfaces measurement task
used for applications which require highest such as analog, Ethernet and EtherCAT • Easy to replace: all sensors can be
precision and stability with a resolution enable connection to modern machines operated without calibration effort with
down to the submicrometer. Thanks to and systems. Settings can be made via the all controllers.
their innovative technology, capacitive user-friendly web interface. • Ease of use via web interface
sensors from Micro-Epsilon provide • Modular, synchronizable multi-channel
highly accurate readings even in harsh Advantages at a glance: controller available
industrial environments. They deliver • Highest precision with subnanometer • Up to eight measurement channels.
measured values down to the nanometer accuracy
range even at extreme temperatures • Excellent temperature stability
and are suitable for operating conditions • Use in ultra-high vacuums and clean Author:
ranging from cryogenic temperatures rooms Dipl.-Ing. Stefan Stelzl
or ultra-high vacuum to dusty industrial • Use in industrial environments, Product Manager
environments or clean room applications. certification according to protection MICRO-EPSILON MESSTECHNIK GmbH
Capacitive sensors from Micro-Epsilon class IP68 Tel.: +49 8542 168 0, Fax: +49 8542 168 90
also provide long-term stability as there • Enormous application versatility Web: www.micro-epsilon.com
www.mtwmag.com AUGUST 2022 MACHINE TOOLS WORLD 55
TECH INNOVATION
Concepts for communication and
Signal Evaluation
Machine safety in intralogistics – best when networked
When it comes to machine
safety in conveyor and storage
technology systems, it’s vital
that the topic of ‘networking’ is
on the agenda, ow-ing to the
extensive nature of the systems,
and the numerous and dif-ferent
safety switchgear devices that
they contain. With a sophisticat-
ed networking concept, you can
achieve multiple goals in one go
– transparency in communication,
‘lean’ wiring and intelligent linking
of different system areas. Here,
system engineers can choose from Fig. 1: In intralogistics systems, alternative wiring concepts for
safety switchgear offer particular benefits.
a number of different options.
he fundamental principle of and storage systems? Irrespective of The trend: networking instead of
machine safety is no different in the specific and individual requirements, individual wiring As intralogistics often
Tintralogistics than in production there should be a sophisticated concept involves larger systems with numerous
or assembly: wherever humans and in place for each and every hazard point danger areas and corresponding
machines work together, humans need to that ensures the best possible integration protection needs, it is one sector in which
be protected. However, in intralogistics, into workplace workflows. This will create the networking of safety switchgear
systems are often very extensive, and the prerequisite for high productivity and devices has been fairly well established
there are many and different ‘interfaces’ minimise any incentive there might be from the outset. This has meant the
to staff, such as transfer stations. Also to tamper with the protective device (a replacement of traditional individual
typical are the high level of automation frequent cause of occupational accidents). wiring of each switchgear device with
and, in some cases, the extremely high efficient, network-like wiring concepts.
product turnover rates. This places high Optoelectronics or guards? There is a range of options available here,
requirements on the productivity and This kind of concept also includes a clear one of which is the AS-Interface Safety at
failure reliability of systems. Moreover, view of the process and indication of the Work (AS- i SaW) safety bus.
in some task areas – such as automated operating states of safety switchgear
palletisation – the components being devices. As guards often complicate AS-i SaW: minimal wiring effort
handled are comparatively heavy. This workflows (e.g. when packages are The AS-i-Safety standard not only
brings an elevated risk of injury. moved into and out of the danger area), facilitates rapid installation with minimal
the use of optoelectronics may be wiring effort – it often saves on several
Looking for sophisticated concepts more suitable. This also applies to area hundred metres of wire for a single
So what does this mean when it comes to protection around packaging machines, application – it also offers maximum
‘designing’ machine safety for conveying for example. flexibility, e.g. in the event of system
56 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
Fig. 2: The components of a practical Fig. 3: Widespread intralogistics: optoelectronic protective devices allow flexibility
safety solution. A view of the process, in safe materials handling.
operating elements close to the door
handle, information about the operating
state of the safety switchgear device.
modifications or new requirements and
safety requirements.
Another advantage is the
comprehensive range of diagnostics
functions. These make for more rapid
identification of the source of error in
the event of irregularities or faults. This
is particularly beneficial in the case of
extensive, complex systems, and can
help to reduce downtimes significantly.
For these reasons, many intralogistics
systems that Schmersal equips with Fig. 4: As many as eight safety switchgear devices can be connected in the field via
safety systems are networked using the Safety Fieldbox. The data are captured and forwarded collectively. This saves
AS-i SaW. This networking is also made on wiring.
easier because of the number of series
of safety switchgear device (including control modules via the PROFINET/ requirements of complex systems
optoelectronics and operating units) that PROFIsafe protocol. The flexibility of the and machinery. Moreover, additional
are available as ‘AS versions’, i.e. with system will be further enhanced in the transmission of all diagnostics signals
integral AS-i SaW interface. future, with the user having a choice of from connected devices ensures optimum
versions with connection to EtherNet/IP process transparency. Plus, increasingly
Alternative – the Safety Fieldbox CIP Safety and EtherCAT FSoE. important as an argument is the saving
The ‘Safety Fieldbox’ system can also be that bus systems can achieve on
used as an alternative to the AS-Interface Two solutions, common objectives resources like plastic and copper.
Safety at Work. A Safety Fieldbox Both solution concepts feature
enables field connection of up to eight straightforward installation and Capture and evaluate operational
safety switchgear devices of different commissioning. What’s more, both signals via SD 4.0
types. Here, safety switchgear devices alternatives offer potential for cost If a user only wishes to capture and
only occupy a single device connection savings thanks to extensive diagnostics evaluate operational, i.e. non-safety-
in each case, irrespective of whether it’s data and straightforward installation related signals, the SD System solution
a sensor or interlock. Both the safety- and wiring. Additionally, both solutions offers a third way. This system allows
related and the operational signals are offer extreme flexibility when it comes electronic safety sensors and solenoid
captured and connected to higher-level to adapting the individual safety interlocks to transmit comprehensive
www.mtwmag.com AUGUST 2022 MACHINE TOOLS WORLD 57
TECH INNOVATION
status and diagnostic data to a higher-
level machine controller.
A new feature of the SD bus is the
significantly expanded networking
option to include higher levels. A
prerequisite for this is the connection
to OPC UA as a standardised protocol
for M2M communication, which has
the advantage of better visualisation
of diagnostic information collected
in the field, and better access via
mobile devices such as tablets and
smartphones. This helps to facilitate Fig. 5: Versatile and flexible: the SD 4.0 data bus enables integration of safety
switchgear devices into preventive maintenance concepts.
predictive maintenance and additional
concepts as part of Industry 4.0. end devices to pair with them. It is only terms of installation effort and flexibility,
logical that alternative wiring concepts particularly in intralogistics.
Outlook – alternative wiring are undergoing further development.
concepts are coming New versions of the Safety Fieldbox are
The examples and the three bus systems conceivable, for example, perhaps with
make one thing clear – alternatives to additional functions and in combination Author:
traditional wiring in safety circuits are of with switchgear devices. Plus, doing Ulrich Bernhardt,
particular use in intralogistics systems. away with hardwired communication in Head of Sales for Controls,
There are established concepts from its entirety in favour of wireless safety Email: [email protected]
which to choose, and the appropriate system would introduce benefits in Website: www.schmersal.in
58 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
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TECH INNOVATION
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are a boon in providing cutting edge
solutions to manufacturing industries
very sector has seen The codes, on the other hand, may be
transformations and advancements sliced or modified depending on its
Eover the years. The days of area of application. The machine unit
numerical controls being solely about is connected to the microcontroller
servo mechanisms are long gone. unit or controller, which stores the
We are now living in the era of CNC coded programs. With the constant
(Computerized Numerical Control) advancement in technology, CNC systems
systems. These control systems have have found use in a variety of industries,
aided in a variety of ways, ranging from including electronics and healthcare.
simple turning to complex machining. When it comes to the manufacturing
The controllers that operate these CNC sector in India, CNC machines have had a
systems are even more fascinating. significant positive impact. They’re known
Mitsubishi Electric looks ahead to partner to provide a slew of advantages, including
with the brands that are focused on increased productivity, higher-quality
MASAYA TAKEDA
global and future-oriented development. products, shorter development times, and General Manager, CNC-Systems
CNC stands for Computer Numerical higher profits. Without CNC machines, Mitsubishi Electric India Pvt. Ltd.
Control, and it refers to the concept you’d have to hire more workers, face
of controlling machine tools with a difficulties replicating a specific product, factors, traditional machinery can be quite
computer. A CNC (Computer Numerical and deal with a slew of other challenges. costly.
Control) machine is an electro mechanical These machines are employed widely However, this is not the case with CNC
device that uses computer programming in the aerospace, electronics, defense, machines. As fewer people are required
inputs for the operation of machine manufacturing, industrial, and medical to operate these machines, labor costs are
shop tools. CNC machining, on the other domains. reduced.
hand, is a widely used process in the
manufacturing industry. Advantages of CNC Machines- 3. Increases the number of production
CNC machines have a number of options
An Overview of CNC Systems: advantages, including: - Your production processes will be boosted
Computerized Numerical Control (CNC) 1. Making mass production easier by the easy-to-use CNC machines. CNC
systems is an automated method of CNC machining makes more sense than software assists you to create products
controlling machine tools, 3D printers, conventional machining when there is a that would be nearly impossible to make
and other devices through the use of high demand for a product, and you need by hand or with traditional machinery.
software-programmed micro controllers. to manufacture the same piece over and
CNC systems have helped in achieving over. 4. This is the Digital Era’s Machinery.
the required specifications and output in Everyone nowadays wants to adapt the
a much faster manner, with little or no 2. Manpower Optimization and Safety trends of the digital era and become tech-
manual intervention. When using traditional machinery, you’ll savvy. CNC machines allow you to do just
CNC systems are controlled by also need to hire experts and other that. By virtue of their operation, CNC
sequential programs such as G-code staff who can deal with the machine. machines use computers for controlling
or M-code, which are written by Then there are the ongoing costs of machine tools which results in reduced
coders or generated by Computer- maintenance and repairs, which must development time, increased cost savings,
Aided Manufacturing (CAM) systems. be considered. Because of all of these and higher profits.
60 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
TECH INNOVATION
5. Assists in the production of high- Mitsubishi Electric India has always • CNC Service Support (Optional):
quality products prioritized product and service Through a dedicated toll-free line, the
Several customers are currently facing improvement, with a focus on delivering company provides round-the-clock
issues with the quality of their products. high-performance and cost-effective telephone support.
This is a challenge that can easily be solutions. In the similar vein, the company
solved if CNC machines are introduced has introduced a new Extended Warranty The following CNCs from Mitsubishi
into the Indian manufacturing industry. Contract (EWC) for specific Computerized Electric India are covered under the
CNC machines allow you to make the Numerical Controllers in order to help the extended warranty contract:
exact same precise cut every time, while customers with better services. • ECONOMICAL: E70/E80 series with
maintaining consistent quality. This ensures prompt responses, reliable turning/grinding/gantry machines for
Mitsubishi Electric, a global leader in technologies, and a user-friendly support cost-effective controllers.
the sales and manufacturing of electrical system for clients all over India, resulting in • STANDARD: M60/M70/E70/M80/E80
and electronic products and systems, better after-sales services. series for standard controllers.
offers Computerized Numerical Controllers • CUSTOM: Windows/customized
(CNCs) that are smoother, faster, and Benefits of the Extended Warranty controllers, including the C70/C80
easier to use than ever before and offer Contract scheme offered by Mitsubishi series, for Japanese and Taiwanese
higher accuracy. The M800/M80 Series, Electric India: machine tool builders,
E80 Series, C80 Series, and other CNC • Priority Response: With the EWC, you
control systems are offered by the can rest assured that as soon as you 2) Preventive Maintenance (PM): It’s
company. call company’s service team to report a important to have a proper preventive
These CNC features help in the breakdown, service engineers will swing maintenance plan in place to keep shop
production of high-quality products with into action to find a solution for the machines running smoothly. Routine
the utmost efficiency and standardized problem caused. inspections help the customers improve
quality. • Low Operating Costs: The company output efficiencies, increased uptime, and
guarantees that there will be minimal improved profit margins.
6. It Increases Productivity downtime and that the machine’s
CNC tremendously increases productivity lifespan will be extended. 3) CNC SS24 Round the Clock Support:
for machine tools as the machinery can • Low EWC Price: The EWC is available Mitsubishi Electric has a dedicated toll-free
be automatically run without requiring in the market at an attractive price when line that is available 24 hours a day and7
continuous attention from their operator. compared to other leaders in the market. days a week. At the toll-free number
The wide range of CNCs offered • Lower Breakdown Time: The company and via email, the company’s CNC front
by Mitsubishi Electric India enables has a set of highly trained and well- engineers are available 24x7 to provide
businesses to achieve smoother and faster equipped engineers, and keep track of technical support to ensure hassle-free
operations as well as a higher level of all installed products and their service operations for the registered customers.
product finish. At the same time, it allows histories in their service management
for increased productivity and profitability software to ensure that machines are 4) Working to Make India Self-Sufficient:
in operations. repaired as quickly as possible. Mitsubishi Electric India’s Computerized
Due to the outstanding features, the • Free Inspection Visit: At the time Numerical Controllers (CNCs) aspire
CNC products offered by Mitsubishi of purchase of the EWC, Mitsubishi to be a trusted partner for businesses
Electric are proving to be extremely Electric India’s CNC will conduct a free seeking global and long-term growth.
useful for the Indian manufacturing machine evaluation. This benefits the The company is also assisting India’s
industry. Aside from the above-mentioned customer because they can learn about manufacturing industry with solutions
advantages, they are also energy-efficient, the machine’s health and condition and that target specific growth segments for
have a lower environmental impact, and plan production and maintenance ahead the country. This step is being taken to
ensure less wastage of time. support the government’s ‘Make in India’
• No hidden costs: The contract covers initiative among manufacturers across
Initiatives by Mitsubishi Electric engineers’ travel and lodging, as well as the country and ensure that Atmanirbhar
that Support the Industry freight charges for shipments and part Bharat comes into practice with high
1) Extended Warranty returns. There are no additional fees. quality and reliable solutions.
62 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
6 - 8 September 2022
Messe Essen, Germany
Register For Your FREE Pass to JOIN THE INDUSTRY:
Europe’s Largest
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EVENT
4,500+ 250+ 60+
ATTENDEES EXHIBITORS SPEAKERS
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conference from these industries. The free-to-attend event features the full range of lubrication and bearing
solutions, spanning each value-chain, from raw chemicals and additives, instrumentation, equipment,
manufacturing and testing solutions, to cutting edge finished lubricants and the latest bearings for
high-performance applications.
CONFIRMED SPEAKERS:
Conference Themes will
Tanja Illic Juergen Ulmer Include:
Managing Director Country Manager • Lubricants sustainability
Nanol Technologies Chevron Deutschland • Meeting the Evolving Needs
GmbH
of Lubricant Customers
• The Lubricants Supply Chain
– Challenges and Management
Annie Jarquin Apu Gosalia
Director of Global Business Sustainability Expert • Solutions for e-mobility and
Development Adviser, Senator at advanced ICE applications
Kline’s Energy Senate of Economy • Lubricant R&D innovations
Management Consulting Partner at Fokus Zukunft
Business • Gaining energy efficiency in
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Sustainability Director Technical Manager – • Increasing performance for
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International Ltd
Infineum
Lubricants
OEM's
Sustainability Director
Technical Manager –
• Increasing performance for
Maurizio Abbondanza
Prof. Thomas Norrby
• Digitalisation
• Plant lubrication strategies
demanding environments
Business
• Gaining energy efficiency in
Partner at Fokus Zukunft
Management Consulting
Senate of Economy
• Lubricant R&D innovations
Kline’s Energy
Adviser, Senator at
Development
advanced ICE applications
Sustainability Expert
Director of Global Business
• Solutions for e-mobility and
Apu Gosalia
Annie Jarquin
– Challenges and Management
• The Lubricants Supply Chain
of Lubricant Customers
GmbH
• Meeting the Evolving Needs
Nanol Technologies
Chevron Deutschland
Managing Director
• Lubricants sustainability
Country Manager
Tanja Illic
Juergen Ulmer
Include:
Conference Themes will
CONFIRMED SPEAKERS:
high-performance applications.
manufacturing and testing solutions, to cutting edge finished lubricants and the latest bearings for
solutions, spanning each value-chain, from raw chemicals and additives, instrumentation, equipment,
conference from these industries. The free-to-attend event features the full range of lubrication and bearing
Lubricant Expo & The Bearing Show combine together to provide attendees with the largest exhibition and
TWO CONNECTED INDUSTRIES:
EXHIBITORS
SPEAKERS
ATTENDEES
60+
250+
4,500+
EVENT
Register for free
IN-PERSON
Bearings Event
Lubricants &
Europe’s Largest
Register For Your FREE Pass to
Messe Essen, Germany
6 - 8 September 2022
PRODUCTS
SHOWCASE Scan for more Products
Nylon / Polyamide Knitted Seamless
Features & Benefits • Paint Shop
Made Synthetic Nylon or Polyamide • Packing
texturised/ stretch yarn for more wearing • Precision Handling- Assembly
comfort & soft feel. The Nylon offers more • Automotive Assembly
sensitivity & ease at finger tips & less lint • Pharmaceutical.
reduces the chance of contamination of
material handled. The gloves in 13 & 15
gauge offer more lighter & sensitivity of
finger tips recommended for precision work.
These gloves are available in different colours
options like White, Blue, Black, Grey etc.. &
sizes options from M to XL. The Nylon/Cotton
Plated Gloves made to increase protection &
also to provide wearing comfort to absorbe
perspiration.
For Product Enquiry Contact Application:
Marvel Gloves Industries • Mechanical Protection
[email protected] • Cleaning
www.marvelgloves.com
High Speed All Geared Lathe
STANDARD ACCESSORIES : • 2 -Axis DRO (Digital
• 3 - Jaw Self Centering True Chuck, Read Out),
• Steady Rest • Rear Splash Guard,
• Follow Rest, • Quiek Change Tool Post
• Face Plate, • Taper Turning
• Coolant System. Altachment,
• Machine Lamp, • Key Way Milling
• Centre Sleeve, Attachment,
• Centre, • Tool Post Grinder,
• Oil Gun, • Driving Plate,
• lnstruction Manual • Revolving Centre,
• Pipe Centre,
OPTIONAL ACCESSORIES : • Anti Vibration Pad. For Product Enquiry Contact
• 4 -Jaw Independent Dog Chuck, Bhavya Machine Tools
www.bhavyamachinetools.com
64 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
AD INDEX
COMPANY NAME PG. NO. COMPANY NAME PG. NO. COMPANY NAME PG. NO.
99MNHANCE I MMC HARDMETAL INSIDE
INDUSTRIAL SERVICES 9 INDIA PVT. LTD. FRONT
COVER
IFFE EXPO - 2022 18
A MMMM EXPO - 2022 65
INSIDE
ISCAR INDIA LIMITED FALSE
AAROH MARKETING 31 COVER O
COMPANY
J ORIENT TOOLS 25
ACCUSHARP CUTTING 29
TOOLS PVT. LTD.
INSIDE P
JYOTI CNC
AUTOMATION LTD. BACK
AHANA HOLIDAYS 47 COVER
POWERTOOL & 59
WELDTECH EXPO - 2023
ANCA MACHINE 1 L
TOOLS PRIVATE LTD
PROSTARM INFO
LAKSHMI MACHINE 5 SYSTEMS LTD 41
ATQ METRO 7 WORKS LIMITED
LASER TECHNOLOGIES Q
B PVT. LTD. 35
QUAKER HOUGHTON 27
BHAVYA MACHINE TOOLS 37 LUBRICANT EXPO - 2022 63
QVI INDIA PVT. LTD. 17
M
D
R
DECELER VIBROTEK M.S. TOOLS &
CONTROLS PVT. LTD. 39 MANUFACTURING 3
COMPANY PVT. LTD.
RAJKOT MACHINE 61
TOOLS SHOW - 2022
DIJET INDUSTRIAL 19
CO. LTD. MASTERCAM INDIA 15
S
F MATRIX MACHINE TOOL
(COVENTRY) LIMITED 13 SUPERSLIDES &
BALLSCREWS CO. 43
FACCIN S. P. A. 11 INDIA PVT LTD (PMI)
MGM-VARVEL POWER
TRANSMISSION PVT LTD 45
G T
GROB MACHINE TOOLS 33 MICROMATIC MACHINE BACK TRUCUT PRECISION FALSE
INDIA PVT. LTD. TOOLS PRIVATE LIMITED PAGE TOOLS PVT. LTD. COVER
66 MACHINE TOOLS WORLD AUGUST 2022 www.mtwmag.com
PUMPS & VALVES
DX Series
Turning & Turn-Mill Center
AX Series
High Precision Turn-Mill Center
VMC Performance Series
Vertical Machining Center
HX Series
Horizontal Machining Center
VTL Series
Vertical Turning Center
DIE MOULD
MMT_Sept2022.pdf 1 13-08-2022 04:10 PM
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