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State-of-the-art CNC machine.

State-of-the-art CNC machine in close-up – “Its fast movements are spectacular”

Blogi 02.12.2021

CNC machine is familiar to many, but what is a state-of-the-art CNC machine? In a nutshell, it is a much faster CNC machine than any other CNC milling machine and capable of higher accelerations in particular.

Speed, in turn, enables significantly higher efficiency in machining and, for example, laser machining.

Because state-of-the-art CNC machine controls higher speeds and accelerations than a conventional machine tool, this places high demands on its mechanical implementation. Especially when the machine should perform the work processes accurately and without vibration.

So what should be considered when designing a machine from the beginning?

Designing a state-of-the-art CNC machine

The state-of-the-art CNC special purpose machine is a demanding machine automation solution that requires both the manufacturer and the customer to commit to several months of cooperation.

From the manufacturer’s point of view, the most important thing is, of course, to listen carefully to the customer’s wishes and design the optimal solution to implement them.

A few technical requirements need to be considered in order to achieve the high dynamics of a CNC machine:

Speed and accelerationState-of-the-art CNC machine is a highly demanding solution.

A state-of-the-art CNC machine is impossible to achieve only by increasing the speeds and accelerations of a standard CNC machine, for example with more powerful motors.

It is important to take into account the deformations and deflections caused by high moments and mass inertia forces, which thus impair the accuracy of the machine.

The strain produced by accelerations can also lead to increased clearances or even transmission failure. For this reason, in high-dynamic machines, it is worth favoring linear motors in which the movement is carried out without any mechanical transmission.

Mass

The large mass causes problems in fast movements in the form of, among other things, high power requirements and additional stress on the frame and components.

It is therefore advisable to reduce the moving mass to a minimum, for example by using lighter materials instead of steel in the body parts.

Rigidness

However, not all materials can be used to reduce weight.

The machine must maintain its rigid structure to ensure the final quality of machining. Meeting the requirements that intersect with each other therefore requires special skills and care from mechanical design.

Case: A state-of-the-art CNC machine implemented by Metecno Oy

We recently built a state-of-the-art 3-axis CNC machine to meet the needs of a customer company, capable of delivering up to 1.5G acceleration to the axes without significantly compromising accuracy.

Here are the most interesting details about the machine:

  • Super fast. The machine is capable of rapid movements at 100 m / min. top speeds and up to 2G accelerations.
  • The moving body pieces were innovatively made of carbon fiber, which made the moving mass light.
  • The movements were performed with linear motors, as they minimized the mechanical clearances in the transmission that in general should be kept to a minimum in dynamic machines.
"The fast movements produced by a state-of-the-art CNC machine are spectacular when the machine does not vibrate and the work process is constant from time to time until the end result."

This kind of machine has enormous application possibilities in both mechanical and laser machining.

We are an expert in customised CNC machines that enhance industrial production. Contact us when your business, regardless of material, requires a state-of-the-art CNC machine!


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Digital Twin a New Method at Metecno – Smart Modelling for the Benefit of the Customer

Blog 01.07.2021
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Digital Twin of MeteMAN Special Purpose Machines and KUKA Robots.
The digital twin is a virtual simulation model produced by a software, a copy of the intended machine solution. A smart digital equivalent of a physical end result. An innovation that is ready to change both the traditional ways of working in mechanical engineering and the ways for companies to grow in the midst of the digital revolution. It is an old method, which has only begun to be used more widely in recent years.

The change could be compared to the time when engineers moved to work from pen and paper to computers. In the future, a machine solution in the making can be seen in realistic operation on the computer screen, and with the data obtained from the simulation model, the machine can be developed even before its manufacturing starts.

Digital Twin - KUKA Sim Pro.The Benefits of the Digital Twin

The main goal and at the same time the real benefit of the digital twin is to save time, effort and money.

It can be used to avoid error solutions in mechanical engineering when the robot cell or production unit to be built is seen in virtual operation even before the components are ordered.

Based on the simulation, the system designer and the customer can jointly assess whether it makes sense to manufacture the device with the intended specs.

If not, the information provided by the digital twin can address problem areas, for example the external dimensions of the solution. The digital twin provides an advanced mean for making early, cost-effective corrective actions without physical testing.

Its particular benefit is the ability to determine the life cycle of a machine. The digital twin makes it possible to schedule maintenance on the machine and even predict component wear.

Lots of Potential for Design Optimisation

It is no longer necessary to complete assembly to you see what potential errors need to be corrected right after the machine, cell or production line is put into operation.

The digital twin eliminates the usual worries of solution functionality, lead times, and even payback time for an investment. Also, the always important safety aspects can be better ensured with the help of the digital twin.

Essential to the use of the digital twin is data transfer; you don’t have to be content with only observing the modeling on the screen, but the twin provides real-time, valid data on the operation of the machine or robot during an assignment. This in turn makes it possible to optimise even small details with the knowledge that the design time used for optimisation will be value for money.

The data transfer to the upper control system takes place via the OPC UA interface, so that the interaction of PLC logic, HMI, actuators and robots can be realistically configured, developed and tested. FAT tests also include virtual deployment. Virtual deployment significantly reduces the time required for the actual physical deployment at the customer’s premises when the operation of the solution has already been digitally verified. The simulation also generates data on the process, which can be cleverly visualized with built-in tools.

Digital Twin Provides Data.Digital Twin at Metecno Oy

At Metecno Oy, we have decided to start utilizing the potential of the digital twin. The first tool generating a digital twin we will introduce will be the KUKA Sim Pro.

The simulation program developed by Visual Components can be used to accurately model and collect information about the operation of KUKA robots in a production environment. Of course, the digital twin can be produced with numerous other software programs of which some of them we may introduce in the near future.

For a Better Offer

KUKA Sim Pro is closely involved in Metecno Oy’s service offering for both robotics applications and MetePRE preplanning.

As a result of the MetePRE preplanning, we will be able to offer a ready-made virtual presentation of KUKA’s robot as part of the production cell on a case-by-case basis in the future. With further user experiences, we can expand our service offering in digital twin applications, as they are widely available in terms of equipment, processes and systems.

Further information

Matti Metsähonkala, CEO
+358 20 741 6210
matti.metsahonkala@metecno.fi