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AI can provide significant benefits to production processes that involve CNC (Computer Numerical Control) machines, which are used to automate the production of complex parts with high precision. Here are some ways that AI can help improve production processes with CNC machines:

1. Predictive Maintenance: AI can monitor the performance of CNC machines and detect early signs of wear and tear, allowing maintenance teams to schedule preventative maintenance before a failure occurs. This reduces the risk of unexpected downtime and extends the lifespan of the machines.
2. Quality Control: AI can analyze data from sensors on the CNC machines to detect anomalies in the production process that could lead to defective parts. This allows production teams to quickly identify and fix any issues before they become larger problems, reducing waste and improving the quality of the final product.
3. Optimization: AI can analyze data on past production runs and use machine learning algorithms to optimize the CNC machine settings for future runs. This can improve production efficiency, reduce production time, and decrease the cost of production.
4. Virtual Simulation: AI can create virtual simulations of the production process using digital twin technology. This allows production teams to test different scenarios and optimize the production process before running it on the actual CNC machines, reducing the risk of errors and improving the final product.
5. Real-time Decision Making: AI can provide real-time data analysis to production teams, allowing them to make informed decisions quickly. For example, if a CNC machine encounters an issue during production, AI can quickly analyze the data and recommend the best course of action, reducing downtime and improving production efficiency.

New energy vehicles

The term new energy vehicles (NEV) refers to plug-in electric vehicles, which include battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and fuel cell electric vehicles (FCEVs), also called hydrogen vehicles. This term is often used in Chinese territory, referred simply to as electric vehicles in other parts of the world.

New energy vehicles and hybrid vehicles are changing the transportation industry departing from conventional fossil-fueled vehicles towards a more sustainable and greener technology. The applications and functioning of each type of NEV are different, however, the non-conventional vehicle market is expected to grow exponentially in the next two decades.

1. The status of new energy vehicles

According to recent studies, the global market for New Energy Vehicles is growing continuously at an annual rate of approximately 22% and is expected to grow from 8.1 million units to 39.21 million units by 2030 without taking into consideration alternative fuels such as hydrogen and bio-combustibles. The machining parts have a big market.

1.1 The background of new energy vehicle

New alternatives for internal combustion cars started developing decades ago, however, electric cars entered the global market around 2010 when concerns about pollution impact started to hit at an international scale.

Nowadays, the automobile industry assimilated the greener energy initiative among their business goals, and big automobile and tech brands such as Tesla, Nissan, and Volvo joined the new energy vehicle market, especially around electric and hybrid vehicles.

In the last decade, China has become the largest seller of plug-in electric passenger cars in the world and new energy vehicles have more than doubled their sales from 2015 to 2020, selling over a million units. And many China machining vehicle parts manufacturer grows up very fast.

1.2 Electric vehicle and hydrogen vehicle

Electric vehicles, also called battery electric vehicles (BEVs), use electricity instead of internal combustion to run the engine. These vehicles use a large traction battery pack to power the electric motor and must be recharged with a piece of outer charging equipment or station to maintain the electric supply to the engine.

On the other hand, hydrogen vehicles (fuel cell electric vehicles) produce electricity using a fuel cell powered by hydrogen instead of drawing electricity from a battery like regular electric vehicles. In this case, the vehicle is designed so the hydrogen fuel cell has the appropriate size to power the electric motor and stored energy. Hydrogen cells don’t generate emissions or by-products during the energy conversion, since hydrogen is a clean (not-fossil) fuel.

1.3 The famous brand of new energy vehicle

As stated above, many brands and companies have joined the new energy vehicle market worldwide, however, the industry leader is Tesla Motors without any doubt. The company led by famous entrepreneur Elon Musk is the number one seller and manufacturer of electric and autonomous vehicles, electric traction motors, electric machining traction motors parts, independent battery motors, and machining battery motors parts.

With a focus on vision-based solutions for auto-piloting vehicles, Tesla mass produces autonomous driving cars in the United States combining green technologies with intelligence and technology. They focused on creating powerful vehicle batteries and building multiple charging facilities for their drivers. Sylue is a lucky machining parts company, which is a machining parts supplier of Tesla Europe.

Other only-electric automobile companies are gaining popularity around the world including Li Auto, Rivian, and BYD Auto, the last one being the world’s best-selling manufacturer of highway-legal light-duty plug-in electric vehicles in 2016.

2. The development trend of new energy vehicles

Although fuel cell electric technology is growing in importance in the clean transportation movement, the automotive industry nowadays is more oriented toward improving the battery range and autonomy. Also, as long as the machining parts production technology improved, they help battery to be improved.

In this sense, the key to developing electric vehicles with longer driving changes is to improve the characteristics of batteries to gain higher performances without harming the environment. In the early stages of electric car manufacturing, lead acid batteries were the first option for energy supply.

However, advancements have been made to improve their performance by trying new materials in battery composition and the CNC machining technology improve the battery housing, The alloys of lithium with phosphate and manganese have shown successful results in this matter. Likewise, manufacturers lean towards the use of gel and silicon batteries to replace common lead acid batteries without the need to significantly increase the price of vehicles.

2.1 The new energy vehicle will be the most important part of automotive industry in the future (Carbon neutral agreement)

In 2015 the United Nations gathered to commit first-world countries and industrial powers to the Net Zero initiative, and as part of this agreement, nations agreed to reduce carbon emissions to a minimum and establish a road to emission-free transportation, considering the impact that fossil fuels and the energy sector have on the environment.

In this sense, international and national policies are focusing on achieving carbon neutrality before the year 2050, investing millions of dollars to transform the energy sector and include renewable energy and fuel alternatives to achieve the zero emissions goal. Hence, the new energy vehicle market is predicted to keep growing worldwide, expecting to become the first option for buyers in the car market by the year 2060.

2.2 Electric vehicle will be more popular – green energy and intelligence system

Due to their scale, car markets create millions of job opportunities, specifically in the electric vehicle supply chain including CNC machining parts, from the investigation of advanced materials for battery packs to power electronics, machining, engineering, motor manufacturing, assembling, and more. Electric vehicles promote the pace of innovation in the transport sectors, as part of the green energy initiative.

Electric car manufacturers are focusing on decreasing battery costs to make new energy vehicles affordable and incorporating artificial intelligence algorithms and controllers to improve driving range and optimize energy conservation.

3. The application of machining parts in new energy vehicles

As the new energy vehicle industry becomes more competitive, efforts to implement data-driven manufacturing technology and advanced machining tools will increase to meet high-performance standards. As the electric vehicle market grows, the demand for CNC machining parts such as gear wheels, transmission components, compressors, battery cells, and trays will increase exponentially. This involves tighter tolerances in machining processes and advanced/updated grinding, milling and drilling methods.

3.1 Machining parts in vehicle body and chassis system

Several parts of the vehicle skeleton or chassis are made of plastic polymers nowadays, where molding technology plays an important role. The frame or main structure of a car is made of metal alloys with high impact and tension resistance. However, laser CNC machines aid engineers in the manufacturing process of roof panels, bumpers, fenders, and other machinining parts of the car’s body system.

3.2. Machining parts in vehicle braking system

The braking system in new energy vehicles is quite similar to the internal combustion cars, with the only difference being that electric vehicles use an electric-powered system to trigger the brakes. However, if the power supply runs out or fails they still have the regular hydraulic brake system installed.

The main parts of the braking system such as braking pads, brake discs, plates, studs, and bearings are often mass-produced with CNC machines with lathes and milling tools. Especially the CNC machining parts with tight tolerances such as wheel bearings and adjustment ratchets.

3.3 Machining parts in the vehicle steering system

A key part of the steering system in any automobile (new energy vehicles and conventional vehicles) is the steering gearbox. Gearboxes are also part of the transmission system with shafts and gear components allowing vehicle movement. These machining parts are also manufactured with CNC machines (mostly drills and mills).

3.4 Machining parts in vehicle drive motor

Just like their internal combustion engine counterparts, electric vehicle motors consist of a chamber, gears, bearings, wires, and so on. The main difference is the source of energy that makes the motor run, in which the electric motors use electromagnetism as the main functioning principle.

What gears, tensors, bearings, chains, pumps, cylinders, bolts, etc., have in common is that they are made of steel and are highly detailed steel machining parts that need CNC machining processes to adjust to the tight tolerances of vehicle performances. This involves drills, mills, lathes, and modern machining centers to manufacture these components.

3.5 Machining parts in vehicle battery

In electric vehicles and new energy vehicles in general battery trays need to be carefully manufactured to ensure the safety and proper functioning of the battery. These trays are usually made of highly detailed aluminum machining parts, needing precise CNC machinery to tap and drill small holes and other characteristic features.

3.6 Machining parts in vehicle drive system

Not to forget that CNC machines are versatile when it comes to different cutting materials. Not only steel and its alloys but also wood, plastic, carbon fiber, and other materials manufactured using CNC lasers or routers.

Routers are useful to cut dashboard frames and manufacture interior panels, gauges, and light cases made with plastic materials to produce plastic CNC machining parts and brass materials to produce brass CNC machining parts.

Manufacturing has moved on from simple cutting tools. Your customers expect you to create high-quality tools from top-end materials, with little room for error. It’s now about the end-to-end process, from sourcing the best materials to providing the best customer experience, and it relies on networked machines and devices. As expectations for cutting tools have changed, so has the equipment you use to stay competitive. The types of CNC machines you use can make or break your position in your toolmaking niche.

Future factories need software as much as hardware

You may have heard of toasters that know when we’re running out of bread, or devices that know they need servicing before we do. They are the cheap thrills of the Internet of Things (IoT). But your factory can also benefit substantially from the Internet of Things, whether it’s predicting when a machine needs to be serviced, monitoring its performance or noticing when stock levels are low. (And, maybe, adding a USB-connected sandwich press to the lunchroom.)

That’s where software becomes key. Smart factories that want the benefits of the IoT rely on connectivity. Machines must have access to software that connects them to an internal network, where every part of the system is able to interact. You might even connect them to a wider network, using information from customer and supplier networks to create more streamlined processes.

Software can have an impact in other ways, too. Our latest product introduced new features to cutting tools, allowing for more complex cutting tool geometries. Some industries have different requirements. For example, aerospace and power generation use hard and soft materials requiring different geometries of cutters for machining them. We have introduced new geometries in software to manufacture special cutters for those processes.

The right software is also a vital component in having different types of CNC machines “talk” to each other. In the past, machines using different protocols, or from different manufacturers, might not have been able to interact with systems inside the factory. Software on the machines allows them to send data to a central location, where it can be distributed in a form every machine – and person – can understand.

Some types of CNC machines can come with you on the journey

 We’ve found that around 95% of machines in use today are 10 years old or less. That’s good news for your factory – often they are still capable of moving to the latest software and adding on accessories that can be used in automation. For example, you might be able to retrofit:

• Laser measurement
• Network connectivity
• Electrical controls
• Operating systems
• Automated processes and libraries

Retrofits mean you can avoid replacing your machines wholesale. Updating them one-by-one will allow you to keep your factory running with minimal downtime and cost so your customer engagement is not disrupted.

Functionality is always improving and expanding. CNC machines aren’t phones – you won’t be installing cutters or grinders that can fit in your pocket or fold up – but a machine of the same size will do more than it does now. The types of CNC machines you were installing fifteen years ago are being replaced by better, faster and more comprehensive models. For example, CNC milling machines have moved from four-axis to six-axis and have added spiralling to their capability. As the machines improve so do their cutting processes and productivity, becoming faster, more precise, and easier to monitor.

Take it one step at a time. Refit or replace machines that will give you the quickest wins, updating your factory’s capability quickly and cost-effectively.

Closed-loop manufacturing is coming – with or without you

Looking to the future is vital. Don’t upgrade or replace your CNC machines without considering what business advantages you are trying to achieve. In your smart factory, you’ll be competing not only on range and precision, but also in terms of specialization, customer experience and time to market. CNC machines that make it easier to build to order will allow you to carry less stock, lower upfront costs and reduce inefficiencies. Market-leading smart factories need to know exactly what their customers need and that’s exactly what newer machines will provide.

And then there’s complete business transformation. Over the next 5-10 years, tool manufacturers will be using their technology to completely eliminate waste – and they’re planning for it already. This ‘closed-loop’ approach to manufacturing means only ordering and using exactly what you need. Nothing will be sent to landfill or left on the factory floor. It’s a world which will be better for the environment, better for customers, and better for your bottom line.

There are many options for bringing your CNC machines into the future. Whether you retrofit software and accessories, or replace your machines with the latest models, you’re investing in a future that’s efficient, connected and more profitable.

Protolabs have launched Design for Manufacturability analysis for 3D printed parts, offering peace of mind to manufacturers across Europe.

It is a significant advancement to the 3D printing offering as it provides added assurance that a part is suitable for manufacturing before committing to production, all entirely online in a matter of seconds.

Protolabs have been supporting customers using the process for CNC and Injection Moulding offerings, and the development brings those benefits of speed and reassurance to the 3D Printing service.  

Andrea Landoni, Protolabs EMEA’s 3D Printing Product Manager, commented: “Additive manufacturing is a brilliant technology, allowing engineers to produce complex parts that were previously too difficult to achieve.

“Whilst the technology offers great flexibility, there are a few limitations that engineers must be aware of and the Design for Manufacturability (DFM) analysis provides that guidance in seconds. The system will instantly highlight all the issues to the user, whether they are critical, such as parts that are too large to be produced, or non-critical, like dimensions that are close to certain thresholds like wall thickness and may not form completely. 

We understand the importance of speed, but ensuring that parts are correct, high quality, and delivered rapidly is critical. Instant analysis means you can have all the advantages of additive manufacturing with even more certainty without sacrificing speed.

Design for Manufacturability processes eliminate lost time incidents for most common issues, preventing engineers from proceeding with their order only to discover there has been an issue hours later. Whilst the vast majority of problems are solved, there are circumstances where the user may still require further support. 

Landoni continued: “Protolabs understand that specific projects require technical consultancy to solve complex issues. In these circumstances, our Application Engineers are still on hand to overcome these challenges and accelerate the process.  

“The Design for Manufacturability analysis supports our Application Engineers by reducing the number of projects they need to get involved in, allowing them to interact with more customers who require their support even faster. “

Mitsubishi Electric Automation introduces iQ Care Remote4U for CNC customers.

Mitsubishi Electric Corporation recently introduced its iQ Care Remote4U Service. The service provides a way for the company’s CNC customers to get their machine tools up-and-running.

iQ Care Remote4U

With this new remote solution, operations may run more smoothly with reduced hindrance from unnecessary, drawn-out downtime. The iQ Care Remote4U platform has been designed to offer a birds-eye view of production that can be accessed and utilized remotely.

Mitsubishi’s remote maintenance solution allows its field service engineers to simultaneously analyze a customer’s CNC machine parameters and alarm history in real-time while troubleshooting errors or issues stopping its proper functioning. 

The service enables the confirmation of system faults or signs of any faults and can estimate machining time in real-time through its Remote Diagnosis Function. 

A mobile terminal, such as a computer, can make use of this. Rapid support through remote diagnosis is made possible through a connection from a terminal installed in a service center to a customer’s machine.

The iQ Care Remote4U service utilizes the Dashboard Function to collect, compile, and perform central management and operating/cost information from many units. This helps customers improve their production processes and reduce operating costs through visualization-based analysis.

In a recent news release, Services Product Manager at Mitsubishi Electric Automation, Adam Gatza, commented, “iQ Care Remote4U gives our customers and engineers a platform to view problems simultaneously giving both parties more confidence in diagnosing the problem in a shorter timeframe and start putting together an action plan on how to fix it.” 

Additional Control Solutions

Mitsubishi has various other CNC machining solutions available to its customers. This includes high-speed/high accuracy machining functions (tool center point control, high-speed, and high accuracy control).

It also includes compensation functions (rotation sensor error compensation, tolerance control, workpiece installation error compensation), IoT functions (MES interface, solution for intelligence), and others.

Mitsubishi’s Direct Robot Control Function 

This function enables robot-friendly CNC control. Users can control and automate Mitsubishi and KUKA robots using G-code by themselves. The Direct Robot Control Function also provides users with a uniform coordinate system for robots and machine tools. 

Additionally, Mitsubishi offers its CNC M800/M80 Series manufacturing execution system (MES) interface function, enabling CNC machining information and machine tool operation status to be sent to MES. 

Mitsubishi hopes this new iQCare Remote system will help users with their CNC operations.