Yamazaki Mazak hosted a special Industry 4.0 open house at the end of November. The four-day event featured a 22-strong machine-line-up at the company’s European Technology Centre in Worcester.
A major focus of the show was the practical implementation of Industry 4.0, specifically how Mazak’s latest CNC Smooth Technology can aid the connectivity of machines and automation systems, improve productivity, reduce maintenance and better integrate with factory management systems.
The three different variants of Smooth CNC were on display at the event: SmoothX, SmoothG and SmoothC. The systems were controlling a number of different machine tools, from entry-level machines to full 5-axis, with many making their UK open house debut.
Smooth CNC facilitates full integration into the factory management system, which is central to Industry 4.0 implementation, through a number of key features.
Easy connectivity
Mazak was also promoting its Smooth Process Support (SPS) suite of software aimed at helping manufacturers achieve sustainable gains in productivity and optimised resource efficiency.
In the face of challenging demands to shorten and individualise production cycles, coupled with rising labour costs and global competition, a comprehensive suite of SPS modules provide solutions for production scheduling, remote and real-time machine monitoring, centralised tool management, program generation and data sharing over a network to streamline management through desktop and mobile devices.
By supporting MT Connect manufacturing protocol, Smooth CNC allows users to access critical machine information aimed at increasing utilisation and providing real-time production feedback. With manufacturing trends continuing towards higher utilisation the technology has been purposely designed to simplify the integration of sophisticated automation systems though a range of industry standard protocol devices.
Alan Mucklow, managing director UK & Ireland sales division at Yamazaki Mazak, commented: “This open house is a clear practical demonstration of how Industry 4.0 can implemented into a modern manufacturing environment.
In reality a lot of this technology has been available on Mazak machines for a number of years. For us it is more of an evolution than a revolution. We are really building on the platforms that we already have to bring both the productivity and efficiency gians that can be achieved through using SPS on the Smooth CNC platform. It enables remote scheduling, monitoring, diagnostics and added connectivity of machines to make communication of data with the user so much easier.
“The principles of Industry 4.0 in terms of interoperability, connectivity, transparency of data all link to the controls and machines at this open house. They are all realisable and available to our customers now.”
“Connectivity and data exchange is key in the factories of the future and was one of the standout criteria during the development of Smooth Technology. Mazak is at the forefront of delivering an all-encompassing and connected manufacturing solution.”
New launches
A number of new machines featured at the event, including Mazak’s latest Multiplex W-200Y turning centre, which is ideally suited to high-volume applications, such as the automotive industry, and features a slant bed for improved chip management.
This latest generation of Multiplex turning centres features Mazak’s SmoothG CNC, which delivers exceptional processing speeds and two-way data communication synonymous with Smooth CNC. The new machine also employs two high power Smooth Mill Drive turrets to perform continuous and simultaneous machining and is also equipped with a 5,000rpm main spindle.
Alongside the Multiplex, Mazak also demonstrated the latest generation of its highly successful multi-tasking machine range, the INTEGREX i-300ST. Featuring a 30kW, 4,000rpm main spindle and second spindle, the i-300ST combines versatility with reliable performance in a compact footprint, capable of processing workpieces up to 1,519mm in length and 658mm in diameter.
A number of Mazak’s successful UK-made machines, which are manufactured on the same site as the open house, were also on display during the event. These included the latest generation Mazak Quick Turn series of performance turning centres, which are designed to offer users the same build quality and level of high precision machinery synonymous with Mazak. The Quick Turn series is ideal for small to medium size manufacturing operations, and offers the same level of connectivity into smart factories through its SmoothG control panel.
Another highlight of the event was the VTC 760C and VTC 800/30SLR, with its large integrated rotary table providing full 5-axis capability, both designed to deliver machining performance and flexibility for a range of cutting applications.
The VTC 760C uses SmoothG technology, whilst the VTC 800/30SLR will showcased Mazak’s ability to deliver cross-manufacturer technology by featuring the Siemens Sinumerik 840sl control. This ensures that the machining centre can deliver the level of connectivity in line with Industry 4.0, in those manufacturing sites operating on pre-existing Siemens control software.
Mazak will also exhibited 4kW and 6kW variants from its Optiplex Fiber laser cutter series. Both machines feature the ability to channel increased beam density and laser energy, combined with a significantly shorter beam wavelength, into a highly precise and efficient cutting process.
Mr Mucklow added: “The new Quick Turn machines that are now being manufactured in the UK are very important development for us. The Quick Turn Nexus, which they replace, has been around for a number of years and has been a hugely successful machine, not just here but also around the world.
“The new Quick Turn machines have a number developments. The first is a new control system, and also a new drive system in the mill turret. This now uses a direct drive integrated motor instead of the old belt and pully system. This brings a lot of advantages, not least the ability to offer 10,000rpm, more flexible toolholding options, either VDI or BMT, better reliability and performance. The power curve and torque, are also enhanced.”
“From a production point of view here in Worcester, we have also rationalised the structure of the machines which makes us much more efficient at building a range of products using a similar base structure. There has been a focus on both customer facing and production facing re-designs. It’s very important for us that the benefits of Industry 4.0 technology are available on a scalable level for all our customers. This technology can be applied equally to Tier 1 companies or OEMs as it can be to the small subcontractor.”
A video of Mazak’s open house is available on the PES video channel at: https://www.pesmedia.com/machining-future-mazak-open-house/
Yamazaki Mazak
