EMO 2023: Take it to the next level

WFL Millturn Technologies will present two turning-boring-milling machines at EMO: the M50 Millturn/3,000mm and the M80X Millturn/4,500mm.

Visitors can see the M80X in action machining a 800mm diameter gear shaft, including measurement of the gear teeth. Both machines feature a new design and are equipped with Siemens Sinumerik One. A mobile robot installed on an automated guided vehicle (AGV) is set to be another highlight of the event and will demonstrate how to load and remove tools and workpieces.

The M80X Millturn with 4,500mm machining length and 1,000mm turning diameter is equipped with a grinding attachment and a vibration-damped Silent Tools Plus boring bar. During the demonstration, gear teeth will be produced using WFL Flanx cycles.

The M50 Millturn/3,000mm will be put through its paces machining a power generation shaft, as well as turbine blades and fir tree, impeller and generator shaft profiles. The demonstration workpiece has a diameter of 600mm and a length of 2,355mm.

WFL turning-boring-milling machines now feature Sinumerik One from Siemens with its new user-friendly interface. Meanwhile, the integrated Simatic S7-1500F PLC enables PLC cycle times that are up to 10 times faster than its predecessor.

Mobile robot automation

The demonstration of a mobile robot installed on an automated guided vehicle (AGV) is set to be a highlight on the WFL stand. It will show how it picks up chuck parts and tools from the warehouse and deposits them on the AGV. The mobile robot will then travel to the machine and, using a camera, scan the QR code to determine its exact position.

The workpiece and tool are loaded and then removed again. For tools, there is an HSK-63 gripper and a Baruffaldi tool turret with Eppinger Quicklock tool holder system for automatic tool changes on the tool turret.

Mobile robots do not need cables or human input and can avoid obstacles. Sensors help to ensure that they move safely and efficiently between locations and interact safely and efficiently with people, forklifts and other material handling equipment.

Using intelligent software in combination with relevant automation solutions is a vital ingredient. As a WFL automation partner, Frai will present its fully expandable mobile robot system.

Smart tools for improved performance

The integration of smart sensors enables detailed tool information and machining states to be called up on the machine control system, tablet or PC. Various sensors installed in the Silent Tools Plus boring bar provide data on load, temperature, deflection and more.

Signals are transmitted via Bluetooth so that the machine can respond interactively to a defined trigger event. The process can be visualised and documented, making it fully transparent. The use of an inductive coupling to power the sensors instead of an accumulator is a completely new feature. The vibration-damped boring bar will be showcased on the M80X Millturn/4,500mm.

In combination with the ‘iControl’ process monitoring system, the operator enjoys a high level of protection for the machine, workpiece and tool to ensure reliable and economical production, especially in prototype production or for small batch sizes.

Measurement on the Millturn

By implementing a wide range of measurement methods, WFL is able to ensure and improve component quality. The automation of all measurement processes is an essential step towards autonomous and low-personnel production.

Thanks to the ability to scan profiles and then evaluate the results, WFL has developed cycles specifically for gearing technology which can be used to measure elements such as tooth flank profile or flank line. The measurements are then checked, analysed and recorded in accordance with industry standards after machining.

Ultrasonic measurement will also be demonstrated live to EMO visitors. The automatically exchangeable ultrasound measuring probe enables a fully automatic measuring process. The large measurement range and automatic, error-proof measuring process are the main advantages. Ultrasonic measurement is ideal for determining and compensating for the tool drift of very deep centre holes.

Operational data acquisition with myWFL

Another EMO highlight will be the myWFL Cockpit operational data acquisition system. Machine and program states over time, productivity and technical availability can all be displayed, either on the machine control system, PC or mobile device via a web browser.

The new myWFL device integrated into the myWFL Cockpit displays the current power data as well as the energy and compressed air consumption of each workpiece.

The Condition Monitoring cycle continuously records the status of the axes and spindles during a measuring run and saves them to the machine control system. Possible changes can easily be detected and displayed via the Condition Monitoring Viewer.

myWFL Health Check performs semi-automated measurements of the B-axis, tailstock and main and counter spindles to check the machine geometry. The software includes cycles and testing instruments to measure and log the geometry.

New design

The new design of WFL's Millturn machines will be showcased at EMO for the first time. Changes include new lettering and a new standard colour. Doors now feature a high-quality, liquid-resistant film.

WFL Millturn Technologies
www.wfl.at
Hall 13, Stand B51