Category: News

In a move to foster advancements in robotics and automation, ABB Robotics has joined forces with MassRobotics, a premier U.S.-based innovation hub and accelerator for robotics startups. This partnership aims to empower emerging companies with cutting-edge technology to develop solutions that address pressing challenges in various industries.

ABB’s Contribution to the Partnership

As part of this collaboration, ABB Robotics will provide MassRobotics with several GoFa 5-kg collaborative robots (cobots) along with licenses for its RobotStudio simulation and programming software. These resources will give startups access to industry-leading tools, enabling them to create, test, and refine innovative robotics applications in a supportive environment.

The GoFa cobot, known for its flexibility and safety features, is designed to perform a variety of tasks such as assembly, material handling, and testing. Its ability to work side-by-side with human operators without the need for protective barriers makes it a versatile addition to MassRobotics’ state-of-the-art facilities.

Advancing the Robotics Ecosystem

MassRobotics provides startups with a collaborative workspace, advanced equipment, and robust support programs to nurture the next generation of robotics companies. ABB’s contribution enhances these resources, equipping innovators with powerful tools to turn their concepts into market-ready products.

John Bubnikovich, President of ABB Robotics, US, highlighted the significance of the partnership:

“By offering our cobots and software to some of the most creative minds in robotics, we’re enabling groundbreaking innovations while gaining valuable insights from this dynamic community. This collaboration reflects ABB’s commitment to pushing the boundaries of automation.”

Tom Ryden, Executive Director of MassRobotics, shared similar enthusiasm:

“ABB’s cobots are a game-changer for our members. With access to these advanced tools, startups can experiment and prototype more effectively, accelerating the development of their robotics solutions. This partnership will undoubtedly inspire new breakthroughs in the field.”

Real-World Applications of GoFa

The GoFa 5-kg cobot is designed to handle tasks across multiple sectors with efficiency and precision. Its ability to operate safely alongside humans eliminates the need for bulky enclosures, making it an ideal choice for modern workplaces aiming to enhance productivity while maintaining safety.

Collaborative Innovation

By combining ABB’s state-of-the-art robotics technology with MassRobotics’ vibrant innovation ecosystem, this partnership is set to accelerate the pace of development in robotics. Together, they aim to address real-world challenges and support startups in creating impactful solutions that shape the future of automation.

For more information on ABB Robotics and MassRobotics, visit their respective websites.

DN Solutions, a leading global manufacturer of precision CNC machine tools, has unveiled its latest entry-level multi-tasking mill-turn machine series at two major international exhibitions: IMTS in Chicago (September 9-14) and AMB in Stuttgart (September 10-14).

As the third-largest CNC machine tool manufacturer worldwide, DN Solutions showcased its new DNX 2100 series, which is designed to offer advanced multi-functional capabilities at a more accessible price point. This new range fills the gap between the company’s popular Puma 2100SY turning centers, equipped with a Y-axis and sub-spindle, and its higher-end SMX 2100S/ST mill-turn models. With the DNX series, manufacturers can access more integrated machining functions than those offered by the Puma models but at a lower cost than the SMX series.

The DNX 2100 models, specifically the DNX 2100SB and DNX 2100S, come equipped with an 8-inch chuck, two built-in spindles (left and right), both capable of reaching 5,000 RPM, as well as a B-axis milling head with a speed of 12,000 RPM. The machine also features an automatic tool changer (ATC) with 40 tools as standard, with an option to upgrade to 60 tools, and it is controlled by the Fanuc 0i-TF Plus system.

This versatile machine series enables manufacturers to efficiently produce complex and high-precision components in a single setup. Compared to traditional Y-axis lathes with driven tools and a sub-spindle, the DNX 2100 offers greater productivity and flexibility, thanks to its larger tool capacity and multi-tasking capabilities.

With two model variants soon to be available, DN Solutions aims to provide component manufacturers with the tools to meet their diverse production needs, while maintaining cost-efficiency and high-quality performance.

The influence of artificial intelligence (AI) on machining is substantial. By offering intelligent suggestions, AI simplifies the programming phase, enabling novice operators to make informed choices and minimizing mistakes. George Chen, Senior Marketing and Business Development Manager at DELMIA, discusses how AI can streamline and enhance machining operations.

The Role of AI in Automation and Manufacturing

In the fields of automation and manufacturing, the incorporation of AI into CNC (Computer Numerical Control) machining is rapidly reshaping the landscape. As organizations strive for greater accuracy, improved efficiency, and cost reduction, AI-enhanced CNC machining stands out as a revolutionary advancement. This article delves into the significant advantages of AI in CNC machining, bolstered by important data and insights highlighting its transformative effects.

Understanding CNC Machine Automation

At its core, CNC machinery operates through automation, utilizing computer programs to dictate the actions of tools such as lathes, mills, and grinders. This automation ensures high levels of precision and consistency throughout manufacturing processes.

With the integration of AI, CNC machines can further enhance their functionality. AI algorithms are capable of optimizing cutting paths, anticipating maintenance needs, and making on-the-fly adjustments during operations. This leads to less waste, quicker production timelines, and lower operating costs.

Machine learning, a key aspect of AI, also plays a vital role in CNC machining by boosting accuracy. By assessing historical performance data and current conditions, machine learning algorithms can predict tool degradation and fine-tune machining settings. This predictive ability extends the lifespan of tools and reduces downtime.

For instance, AI can sift through extensive datasets from prior machining activities to discern trends and enhance future operations, leading to more efficient production timelines and overall productivity improvements.

AI: A New Era for CNC Machining Techniques

CNC machining has long been essential to manufacturing, known for its precision and reliability. However, AI is introducing innovative capabilities that push beyond traditional boundaries, including advancements in predictive maintenance, process optimization, and real-time quality assurance.

1. Precision and Quality Assurance AI improves CNC machining accuracy by utilizing real-time analytics. According to a 2023 Deloitte report, AI-driven quality control can reduce defect rates by nearly 50%. AI systems analyze sensor data from CNC machines, identifying inconsistencies that might escape human attention. This leads to more consistent product quality and greater customer satisfaction.
2. Predictive Maintenance and Cost Efficiency AI is transforming how manufacturers manage equipment maintenance. Research from McKinsey indicates that AI-powered predictive maintenance can lower maintenance costs by up to 25% and decrease unplanned downtime by 30-40%. By evaluating historical data and real-time sensor information, AI can predict potential failures, allowing for timely maintenance that averts costly interruptions.
3. Toolpath Optimization The importance of AI in refining production scheduling cannot be overstated. A 2024 study published in the International Journal of Production Economics revealed that AI-optimized scheduling can enhance production efficiency by up to 20%. AI can automatically generate and refine toolpaths, manage machine availability, and cut lead times, facilitating smoother operations and increased throughput.
4. Advanced Automation Processes The introduction of AI in automating intricate machining tasks significantly boosts productivity. A Deloitte survey shows that nearly 70% of manufacturers implementing smart technologies are using AI to enhance operational efficiency. AI systems can handle setup tasks, tool changes, and adapt to new designs with minimal human oversight, resulting in shorter production cycles and reduced human error.
5. Flexibility and Customization Rapid adaptability to changing production demands is becoming crucial. AI enhances the flexibility of CNC machining by enabling quick adjustments to manufacturing parameters. This discussion highlights the reduced time needed to reconfigure machinery for diverse products and the pivotal role AI systems play in achieving this flexibility. Such adaptability allows manufacturers to meet rising demands for customized and small-batch production without sacrificing efficiency.

Can AI Program CNC Machines?

Absolutely! AI can program CNC machines by utilizing advanced algorithms to automate and enhance various programming facets, such as generating essential G-code and M-code for machine control. Key steps include:

• Evaluating 3D Models: AI examines CAD designs to comprehend the part’s geometry and features.
• Simulating Tool Paths: The system tests different tool paths to identify the most efficient routes, minimizing material waste and machining duration.
• Parameter Optimization: AI fine-tunes machining parameters like feed rates and spindle speeds based on material and equipment capabilities.

For instance, when dealing with complex shapes, AI can ascertain the most effective cutting strategies to ensure precise results, thereby reducing the necessity for manual programming and minimizing errors.

Real-World Applications and Outcomes

Leading companies are already benefiting from AI-enhanced CNC machining:

One prominent utility firm has integrated AI to enhance predictive maintenance and process efficiency, achieving a 20% increase in equipment uptime and a 15% reduction in maintenance expenses. By leveraging AI for machine data analysis and failure predictions, they have enhanced productivity while lowering operational costs through optimized maintenance scheduling.

Similarly, an engineering and technology enterprise that adopted AI in its CNC machining processes saw a remarkable 40% decrease in defect rates. AI-driven quality monitoring continuously analyzes production metrics and sensor data, quickly detecting and addressing discrepancies. This proactive strategy mitigates potential issues before they affect the final product, improving overall quality.

Revolutionizing Machining with AI Innovations

AI-driven solutions, like DELMIA Machining, are leading the charge in automation and manufacturing innovation, significantly refining CNC machining practices. One of their standout features includes the capability to automatically recommend optimal toolpaths based on selected geometries. This feature is particularly advantageous for less experienced users in the programming phase.

When novice programmers tackle new parts, they often struggle to identify the best machining operations. However, an AI-guided toolpath proposal system alleviates this challenge by offering smart recommendations rooted in historical data. This system employs a neural network trained on various common geometries, identifying patterns to suggest suitable machining operations.

The ramifications of this AI functionality are considerable. It streamlines the programming process by delivering informed suggestions, aiding less experienced users in decision-making, and reducing the risk of errors. This automated guidance accelerates setup times and improves machining accuracy, leading to greater efficiency, reduced programming durations, and more consistent product quality for manufacturers.

In response to the rising demand for electric motors within the automotive industry, Comau has introduced an advanced suite of automated machinery tailored for the efficient production of hairpin stators.

With over half a century of experience, Comau has solidified its position as a global provider of assembly and machining solutions for the automotive sector. Their expertise spans the development of industrial robots and IoT platforms. Recently, the company expanded its offerings with a full lineup of machines dedicated to producing hairpin stators—key components in electric motors that power electric vehicles and require specialized production techniques.

New Hairpin Stator Manufacturing Solutions

To meet the evolving needs of electric vehicle manufacturers, Comau has launched an extensive range of machines specifically engineered for hairpin stator production. The new portfolio includes equipment for wire forming, insertion, twisting, and laser welding. Unlike one-size-fits-all systems, these machines are designed with flexibility and scalability in mind, enabling manufacturers to adapt as production requirements evolve.

Each unit has been optimized for a compact footprint and streamlined production setup. The automated process allows for real-time monitoring, ensuring that potential issues are identified early, minimizing downtime. Additionally, Comau focused on energy efficiency during the design phase, in line with the sustainability goals of electric vehicle production.

Advanced Wire Forming and Insertion Technology

The wire forming machine offers a fully automated process that handles tasks such as unwinding, straightening, paint stripping, cutting, 2D numerical control (NC) forming, and 3D mold shaping. The machine achieves a rapid cycle time of under 2 seconds. It also ensures high precision, with less than 0.2 mm deviation during the straightening phase. Configurable options for paint removal allow for either laser or mechanical processes, depending on specific needs.

This machine operates without manual intervention and features a high-speed gantry system for inserting formed wires into the stator. Insulating material is pressed between wires using a corolla press. The insertion machine accommodates various wire shapes, making it versatile for different product types.

Precision in Wire Shaping, Twisting, and Cutting

The process continues with specialized machines for wire widening, twisting, and cutting. These machines leverage precision servo and cam-driven technologies, offering customization based on specific end-product requirements. The design reduces burrs during cutting and ensures smooth twisting actions, with programmable settings for different stator models.

Laser Welding for High-Quality Connections

Comau’s wire welding machine utilizes laser technology to deliver deep weld penetration and high pull-out strength. The system supports multiple welding programs, catering to different part configurations. Manufacturers can choose between a standalone welding unit or a combined cutting and welding solution for increased production efficiency.

Global Production Capabilities

The hairpin stator modules are manufactured at Comau’s E-Motor Technology Center of Excellence in Shanghai. This strategic location allows Comau to efficiently serve a global market while staying connected to one of the world’s most dynamic hubs for electric vehicle development.

Mitsubishi Electric has significantly increased its stake in Realtime Robotics to bolster its advancements in factory automation solutions. This move underscores Mitsubishi’s commitment to integrating Realtime Robotics’ cutting-edge motion planning technology across its industrial automation offerings.

For years, Mitsubishi Electric has been a key player in providing a wide range of factory automation solutions, from PLCs to robotic systems, supporting automation projects in assembly and process industries. Since May 2019, Mitsubishi has been utilizing Realtime Robotics’ proprietary motion planning technology to enhance its industrial robot product line.

In a recent development, Mitsubishi has announced a substantial increase in its initial investment in Realtime Robotics. This strategic decision reaffirms Mitsubishi’s dedication to embracing digital transformation and optimizing technological capabilities.

Motion planning, also known as path planning, is a critical computational process used in robotics, computer animation, and gaming to determine the most efficient movement of objects from one point to another. As automation evolves, motion planning is increasingly applied to other devices like PLCs and CNC machines to optimize their operational efficiency and safety.

Mitsubishi aims to leverage Realtime Robotics’ software and control systems further by integrating motion planning technology into its simulation software. This integration will enable machine builders and robot programmers to develop precise programs and conduct accurate reach studies in a digital environment. Additionally, it supports the creation of digital twins for troubleshooting and maintenance in manufacturing facilities.

Another strategic initiative involves embedding motion planning technology into control system devices such as PLCs, servo drives, and CNC machines. By integrating efficient path calculation technology, Mitsubishi aims to enhance productivity, reduce energy consumption, and optimize operations across manufacturing processes.

As Mitsubishi Electric competes in the competitive landscape of factory automation, its increased investment in Realtime Robotics positions it as a leader in driving digital transformation and optimization within the industry. By expanding its collaboration with Realtime Robotics, Mitsubishi seeks to innovate and integrate advanced technologies into various factory automation devices, aiming to establish itself as a comprehensive digital engineering enterprise.

Ooznest, a UK-based supplier known for RepRap 3D printer components, has launched the Ooznest OX, a high-quality CNC router kit designed for hobbyists.

Building on its origins in 3D printing at Cambridge, Ooznest is expanding into the wider maker community with the Ooznest OX. This new CNC machine allows users to create functional parts from materials such as wood, plastic, and aluminum.

The Ooznest OX is a comprehensive kit aimed at the hobbyist CNC market. It employs the widely favored V-Slot extrusion system, providing the machine with exceptionally smooth and precise linear motion. The machine features NEMA23 stepper motors driving all axes, with GT3 belt motion on the X and Y axes, and an ACME lead screw system for the Z axis. It uses the CNC xPro for motion control and includes cable carriers to ensure safe operation.

The fully assembled Ooznest OX is available now at different price points and sizes to meet various needs. Options include a 500x750mm model priced at £969 and a 1500x1500mm model for £1202.50. For more adventurous makers, a mechanical kit version starts at £570, offering a base platform to customize with different electronics and motors.

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Entering 2024, let’s delve into key events showcasing the latest trends and technologies in CNC machines.

This article explores trade exhibitions, where experts, manufacturers, and enthusiasts convene to share and experience cutting-edge CNC machining advancements.

From bustling exhibitions in Germany to innovative showcases in the USA, these events shape the future landscape of CNC machines. Each exhibition offers professionals an opportunity to explore the latest technologies, forge crucial connections, and immerse themselves in the dynamic world of CNC machining.

We’ll delve into these events, illustrating how they drive progress and foster community engagement. They serve as compasses guiding the trajectory of CNC machine evolution.

The surge in online research popularity has revolutionized exploration and learning about products. Unlike traditional trade shows, platforms like Qviro offer round-the-clock accessibility, empowering users to gather information and make decisions at their own pace, unrestricted by event schedules.

IMTS – International Manufacturing Technology Show: IMTS 2024 showcases cutting-edge technologies such as smart manufacturing and 3D printing. IMTS+ supplements the trade show with streaming presentations, digital content, articles, and technical papers, fostering innovation and shaping the future of manufacturing.

Date: September 9, 2024 – September 14, 2024

Location: McCormick Place, Chicago, Illinois, USA

JIMTOF – Japan International Machine Tool Fair: JIMTOF 2024 in Japan highlights the latest manufacturing innovations. Exhibitors unveil advanced machine tools and automation solutions, making it a global nexus for industry leaders to unveil new products, exchange ideas, and foster international collaborations, reflecting the dynamic progress in machine tools and manufacturing.

Date: November 5, 2024 – November 10, 2024

Location: Tokyo Big Sight, Tokyo, Japan

CIMT – China International Machine Tool Show: China International Machine Tool Show (CIMT) sets a global standard akin to EMO and IMTS. The exhibition features numerous new products, hosts forums, and draws professional visitors, contributing significantly to advancing machinery manufacturing technology and maintaining a pivotal role in the global machine tool industry.

Date: April 12, 2024 – April 17, 2024

MACH: MACH 2024 serves as a vital platform for UK manufacturing, fostering idea exchange, innovative workflows, and industry collaboration. It addresses challenges such as energy costs, labor shortages, and sustainability, offering industry leaders and professionals an avenue to convene, exchange ideas, and enhance manufacturing practices.

Date: April 15, 2024 – April 19, 2024

Location: NEC Birmingham, Birmingham, UK

METAV: METAV attracts 500 exhibitors and 26,000 visitors globally, showcasing innovations in machine tools, manufacturing systems, and related technologies. Attendees can participate in on-site demonstrations and workshops at the METAV Forum, exploring various industry topics.

Date: February 20, 2024 – February 23, 2024

Location: Messe Düsseldorf Düsseldorf, Germany

FABTECH: FABTECH 2024 stands as North America’s premier event for metal forming, fabricating, welding, and finishing. With over 1,500 top suppliers, attendees can explore new solutions, enhance productivity, and stay abreast of the latest technology trends.

Date: October 15, 2024 – October 17, 2024

Location: Orange County Convention Center, Orlando, Florida, USA

MTA Vietnam: MTA Vietnam 2024 offers a valuable platform for exhibitors and visitors alike, featuring talk shows and seminars aimed at modern production businesses. With participants from 17 countries/regions, it presents ample opportunities for networking, partnership building, and goal alignment.

Date: July 2, 2024 – July 5, 2024

Location: Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam

Global Industrie: Global Industrie Paris 2024, held at Paris Nord Villepinte, serves as a dynamic meeting point for the industrial ecosystem, with a focus on cutting-edge robotics technologies.

Date: March 25, 2024 – March 28, 2024

Location: Paris Nord Villepinte, Paris, France

MECSPE: MECSPE, hosted at BolognaFiere, showcases the latest in manufacturing innovations and sustainability efforts, offering valuable insights for industry professionals.

Date: March 6, 2024 – March 8, 2024

Location: BolognaFiere, Bologna, Italy

BI-MU: BI-MU, held at fieramilano, Milan, serves as a prominent international exhibition for the machine tool industry, facilitating networking and business opportunities.

Date: October 9, 2024 – October 12, 2024

Location: fieramilano, Milan, Italy

In conclusion, 2024 features significant global trade exhibitions for CNC machining, spanning various countries and showcasing the forefront of technological advancements. These events not only showcase innovations but also serve as platforms for industry networking and collaboration, driving the future trajectory of CNC machining worldwide. As we anticipate 2025, the industry’s continual growth promises an exciting future for CNC machining on a global scale.

In a bid to bolster its sustainability efforts, Amazon has disclosed its investment in CMC Machinery, a firm pioneering technology aimed at crafting tailor-made boxes, thereby obviating the necessity for disposable plastic packaging.

The Climate Pledge Fund, an initiative dedicated to backing enterprises that can hasten Amazon’s progress towards fulfilling The Climate Pledge commitment, spearheaded this investment. The pledge, endorsed by over 200 global businesses, seeks to expedite the transition to a carbon-neutral economy. The fund, valued at $2 billion, targets companies crafting solutions conducive to achieving net-zero carbon emissions.

Kara Hurst, Amazon’s Vice President overseeing Global Sustainability, expressed enthusiasm for investing in innovative technologies via The Climate Pledge Fund. Hurst emphasized Amazon’s ongoing quest to identify groundbreaking ventures capable of propelling the shift towards a low-carbon future.

CMC Machinery’s groundbreaking technology specializes in crafting bespoke boxes precisely tailored to accommodate the dimensions of each item in an order. This innovation ensures accurately sized packaging, eliminating the necessity for disposable plastic padding while still ensuring the safe transit of goods.

By the close of 2022, Amazon anticipates a 24% reduction in the cubic volume of each box on average, facilitated by CMC Machinery’s technology. Furthermore, the company foresees a significant decline in the usage of plastic air pillows, estimating a reduction of approximately 1 billion units by the end of 2022.

Francesco Ponti, CEO and Strategic Business Development Director of CMC Machinery, lauded the investment as a testament to the enduring partnership between Amazon and CMC Machinery. Ponti underscored the shared commitment towards minimizing the environmental footprint associated with e-commerce packaging, expressing pride in their technology’s role in advancing The Climate Pledge’s objectives and fostering a transition towards a carbon-neutral future.

The future of metalworking in 2024 promises to be shaped by digitalization, smart factories, and the emergence of the industrial metaverse. Hakan Aydogdu, General Manager of Tezmaksan Robot Technologies, sheds light on the transformative trends in manufacturing, emphasizing the importance of adopting user-friendly and adaptable technologies to stay competitive in the evolving metalworking industry.

According to Deloitte’s recent report on the US manufacturing industry, the sector’s annual construction spending reached $201 billion in July 2023, marking a 70% year-over-year increase and laying the groundwork for further growth in 2024. This growth is propelled by various factors, including the demand for lightweight and durable materials like aluminum and titanium in industries such as aerospace and automotive, where energy efficiency is paramount. Additionally, manufacturers are investing in electrification and decarbonization to align with global sustainability goals.

Technological advancements play a crucial role in driving manufacturing growth, with a focus on innovation, research, and product development to explore new markets and attract new customers. But what technologies will drive the metal fabrication industry forward in the coming year? Let’s explore some key trends and technologies that manufacturers should embrace to maintain competitiveness.

Artificial Intelligence (AI) and Machine Learning (ML) In 2024, AI and ML will revolutionize the metalworking landscape, enabling the creation of intricate components and facilitating data-driven decision-making. AI-powered design tools streamline the product development process, while ML algorithms analyze vast datasets to enhance productivity and competitiveness.

Smart Factories and Interconnected Technologies Smart factories, powered by advanced technologies such as AI, 5G, Internet of Things (IoT), and cloud computing, will play a pivotal role in the metalworking industry in 2024. These interconnected factories optimize production processes, enable predictive maintenance, and foster real-time communication between devices, leading to increased efficiency and productivity.

Digital Twins and the Industrial Metaverse Digital twins, virtual replicas of real-world objects and systems, are revolutionizing manufacturing by creating immersive 3D environments for simulating equipment and processes. In 2024, manufacturers will leverage digital twins and the industrial metaverse to enhance collaboration, improve decision-making, and create larger virtual environments that replicate real machines, factories, and cities.

Digitalized CNC Machining Digitalized CNC machining is another key trend for 2024, with machines becoming more automated and interconnected to increase efficiency. IoT sensors, data analysis, and AI tools like ChatGPT are integrated into control systems, enabling predictive maintenance and enhancing productivity on the shop floor.

CubeBOX: A Versatile Solution for Smart Factories CubeBOX, a compact robot cell designed for continuous operation, addresses the industry’s demand for efficiency and flexibility. Its user-friendly software eliminates the need for complex programming, while its lean design and compatibility with various CNC machines make it a versatile solution for manufacturers with diverse needs.

In conclusion, manufacturers must embrace digitalization and interconnected technologies to stay competitive in 2024’s rapidly evolving industrial landscape. By adopting AI, embracing smart factories, leveraging digital twins, and investing in digitalized CNC machining, manufacturers can navigate the challenges and seize the opportunities presented by the future of metalworking.