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ANCA Motion’s Multi-Axis Servo System Conserves 96 Percent Of Energy Wastage

ANCA Motion’s Multi-Axis Servo System Conserves 96 Percent Of Energy Wastage

In a servo motor system, regenerative energy is the energy that returns to a drive when a motor decelerates, and the amount of regenerative energy depends on the deceleration speed and load inertia. In laser cutting machines, the regenerative energy is typically large owing to their fast acceleration/deceleration and heavy mechanical structures.

Energy returned to drives is absorbed by the capacitors on drive’s DC bus. A multi-axis servo drive system does have a big advantage when handling the regenerative energy; the shared DC bus allows more bus capacitance to absorb and store more energy which can be used in the following acceleration cycles.

However, when regenerative energy is too high to be absorbed by the capacitors on DC bus, the excessive energy needs to be managed otherwise it can cause servo drive system failures.

Normally the excess energy is burned off via brake resistors connecting to the drive’s DC bus. This dissipates (and effectively wastes the energy), creating heat in the process.

An alternative solution is to use capacitor modules in the system. This offers a way to slash operating costs, particularly in energy-intensive machine applications involving a lot of deceleration, such as laser cutting.

Both solutions are supported by ANCA Motion’s AMD5x multi-axis servo drive system. The system uses a bussed system architecture, and its power supply unit converts three-phase mains electricity to a DC supply to all bussed drives.

The AMD5x system is highly flexible and is suited to highly demanding CNC applications such as laser cutting. It is suitable for accommodating multiple capacitor modules as well as servo drives.

A frequently asked question about using capacitor modules is about its ROI (Return on Investment). The potential of capacitor modules to save machine operators’ energy costs was explored recently, indicating a surprisingly short payback period.

For the analysis, a laser cutting machine operating at full load in China, two shift-per-day scenario was created, assuming a 0.66 RMB per kilowatt hour electricity price and an Air Conditioner (used to cool the control cabinet) energy efficiency ratio of 3.

The performance of a machine with two capacitor modules in this scenario was compared to that of a machine with a brake resistor only.

The difference in wasted power was unsurprisingly stark. This stood at 4,500W of wastage for the system with no capacitor modules, compared to 180W with. This translated into wasted energy per month of over 2200 KWH (worth about 1,400 RMB) versus 90 KWH (about 60 RMB).

Operating costs – including the initial investment – drew level at around eight months, with these becoming significantly cheaper overall for the system using capacitor modules after that point.

With factories under unprecedented pressure to run to tighter margins and to get smarter with their power use, harnessing and reusing energy rather than burning it up and wasting it is an attractive proposition.   

 

Written by Heng Luo, ANCA Motion Product Manager

 

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ANCA GCX Linear Meets The Needs Of Growing Skiving Cutter Market

ANCA GCX Linear Meets the Needs of Growing Skiving Cutter Market

Launched at the recent EMO Hannover 2019 event in Germany, ANCA’s GCX Linear builds on the best aspects of its proven technology to offer a purpose-built solution for manufacturing and sharpening skiving cutters. With a five-axis CNC grinder powered by LinX linear motor technology on X, Y and Z axes, the GCX Linear also comes with features specially designed for skiving cutters and shaper cutters.

“ANCA is responding to the increasing popularity of skiving and resulting surge in demand for skiving cutters. We want our customers to have a complete solution for manufacturing and sharpening skiving cutters and the GCX Linear will set the new benchmark for skiving cutter grinding,” said Xiaoyu Wang, product manager at ANCA.

Dressing the complex wheel profile is critical, so ANCA developed the latest acoustic emission monitoring system (AEMS), according to Wang.

“AEMS can be taught to pick up the right sound of perfect dressing even in a noisy production environment. Built upon supervised machine learning algorithm, AEMS ensures the wheel profile is dressed within micron accuracy with the least possible time while minimising the reduction in size,” said Wang.

One of the key features of ANCA’s new GCX Linear is the patent pending Motor Temperature Control (MTC), which minimises machine warmup time, and delivers optimal thermal stability during grinding. Smart control algorithm actively manages and maintains the temperature of motorised spindles in the GCX Linear. Benefits delivered by this feature include reduction in machine warmup time—you can start grinding tools sooner, knowing the machine has reached thermal stability—thus improving productivity and machine utilisation.

It also features consistent thermal stability of the spindle over time regardless of changes in spindle load or speed, or spindle cooling coolant temperature. This greatly improves dimensional stability of grinding results.

ANCA’s GCX Linear is powered by its LinX, a linear motor technology for axis motion (X, Y and Z axes). In conjunction with linear scales, LinX helps GCX Linear achieve superior precision and performance. Specially designed for a lifetime of operation in harsh grinding environments, the LinX motors have a cylindrical magnetic field, which means there is no additional down force on the rails or machine base.

With no temperature variations—therefore, there is no need for a separate chiller unit—and being sealed to IP67, there is minimal wear and tear, thus machine accuracy remains over its lifetime. The LinX linear motor has higher axis speed and acceleration, leading to reduced cycle times while maintaining a smooth axis motion.

 

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Getting Ahead In The Medical Market

Getting Ahead in the Medical Market

Here’s how medical instrument manufacturer Mahe Medical has successfully grown their range and market. Article by Duncan Thompson, ANCA.

What does it take to successfully enter a new market? Examples where one factor alone sets up an easy path for success are rare. More typically, success comes from a combination of inputs, some strategically planned, others through serendipity. Such is the case of Mahe Medical who, today, manufactures and sells a growing range of medical instruments.

Markus Heckman, Mahe co-founder and managing director, talks of some decisions and choices made along the way to becoming a successful supplier of medical instruments to global players in the orthopaedic industry.

“My brother and I learned tool grinding skills in my father’s grinding factory. But we made an early decision to move towards the medical tooling market. This allowed me to utilise knowledge picked up in completing my Medical Engineering degree,” says Markus.

Initially, he used the facilities of his father’s factory to grind medical instruments in the evenings. And then in 1993, Mahe Medical was established. Markus was soon joined by his brother, Jochen, and together they continue to work collaboratively in strategic, manufacturing and customer focused aspects of the business.

Markus and Jochen reflect on their decision to use ANCA grinders. “Our first ANCA purchase really came out of perfect timing for both ourselves and ANCA. The company from whom we purchased our first grinding machines was going out of business and we needed a new supplier that could guarantee ongoing support. Right at that time, the ANCA salesman was knocking at our door promoting RGX. Other cheaper options were available, but the immediate benefits of ANCA were obvious in the Cimulator 3D, which at the time was way ahead of anything else offered in the market. Combined with the machine software being so flexible, it was an easy choice. We found we could prepare tools that had geometries not possible on our older machines. This allowed us to work much more collaboratively with our customers to produce exactly the tools they wanted,” said Markus.

Jochen explains the continuing relationship with ANCA. “Our first purchase was based on the technical features of the machine and software which were clearly industry leading. But subsequent machine purchases were equally driven by the fantastic support we have received from ANCA over the years. Whether servicing existing machines or providing technical support for new applications, ANCA has been there with us. Most recently we took the step into producing femoral hip rasps – a whole new application that convinced us ANCA was committed to supporting us.”

This has given Mahe Medical the confidence to branch out and establish a manufacturing site in Southeast Asia. Again, with ANCA being so close by. By doing this, Mahe can now be working with and responding quickly to their customer base in that region. Today, Mahe Medical has 10 ANCA machines installed across its German and Thai manufacturing facilities.

Medical Market Challenges and Future

So, what are the challenges for today for Mahe Medical? “The medical instruments business is extremely competitive,” Markus explains. “Not only do you have regulations to consider, but margins are tight. So, we are constantly talking with ANCA about ways to make our manufacturing processes more efficient and leaner, and to keep our costs down. The FastLoad automation solutions, for example, perfectly met our needs. For a small investment, we get flexible, unmanned production for the small batch sizes we must deal with. This means manufacturing in Germany can still be competitive. This in itself is a benefit, because it brings with it an implicit recognition of German quality.”

And the future for Mahe? The brothers are optimistic and enthusiastic. “We are regularly talking with ANCA to find ways we can be more efficient with manufacturing our new applications or products that can be supported on their machines. Right now, we are closely considering other orthopaedic implant applications,” says Jochen.

For this application, ANCA offer a comprehensive programming solution by integrating Siemens NX-CAM with ANCA’s iGrind software. This makes easy work of programming the ANCA machines for grinding and milling the complex forms for hip rasps and orthopaedic knees. Additionally, services for tooling design ensure parts are accurately and rigidly held during the grinding and milling processes.

“Knowing that ANCA already has experience with this application and will continue to support us, gives us much more confidence as we continue taking steps to grow our business,” concludes Markus.

For companies skilled in cutting tool grinding, the medical industry represents an excellent opportunity for tool makers looking to diversify into a new market with outstanding prospects for ongoing growth, be it in orthopaedic or rotary instruments. Given this, ANCA has an ongoing focus on developing software that meets the needs of the medical tooling application. ANCA’s latest application software release, RN34, introduces an array of new features that allows increasingly complex tool geometries to be created with ease.

 

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EMO 2019: ANCA To Launch Latest Generation Of ToolRoom Software

EMO 2019: ANCA To Launch Latest Generation Of ToolRoom Software

Leading cutting tool manufacture Fraisa, reduced set up from hours to five minutes through the new tool balancing feature in ANCA’s new ToolRoom RN34. A specially designed software package for the aerospace, die mould, general machining and power generation industries, the product will officially launch at EMO 2019. Customers can get improved productivity or minimise chatter through the intuitive design of high performance, complex endmills.

“ToolRoom RN34 is aimed to be the differentiator among many suppliers of endmill manufactures in the industry by allowing customers to design complex geometries through software to achieve increased tool life, productivity, cutting volume and increased quality and precision of the workpiece” says Thomson Mathew, ANCA Software Product Manager.

The constant helix ballnose option, for example, is replaced by a graphical drag-and-drop designer. This ballnose type of tool, with optimised irregular helix curves to reduce vibration, and with near-instant visualisation easily achieved by switching from the 2D projection of the cutting edge to the 3D.

Douglas Franke, Fraisa Production Manager said: “with ANCA’s balancing software we have a tool balanced generally within five minutes. Some of our more complex tooling can take a little longer – up to 20 minutes. This drastically decreased our time in setup on the machine which could take several hours. Our biggest success story has been an aerospace customer who is running our 1” aluminium roughing tool at 25k rpm.”

Lights Out Manufacturing To Be ANCA’s EMO Theme

Toolmakers have always been subject to technological change. Today the future of tool making innovation goes by many names. The Factory of the Future (FoF), the Smart Factory, or Industry 4.0. Whatever it is called, there’s one common factor: it’s revolutionary, and it will redefine and optimise manufacturing processes. ANCA will be showcasing its technology so tool makers understand how they can Build their Factory of the Future at EMO.

  • Reduce wasted materials and time through 3D simulation.
  • Increase grinding efficiencies through informed, data led decisions.
  • Reap the benefits of lights out manufacturing with affordable, easy to use robots.
  • Achieve 100 percent tool accuracy through automated in process measurement.

For tool manufacturers this will be a new landscape that places big data analytics and interconnected technology at the heart of daily work. It means streamlined business operations that allows rapid expansion into new and emerging markets and technology throughout the process to remove the need for human intervention.

Change will not happen in one radical moment. For almost 50 years ANCA has been on the journey to help our customers move towards a smart factory solution. Every world-first technology development we’ve introduced, from 3D simulation software to Laser Plus, our in-process measurement system, to RoboTeach, which makes robotic loaders accessible and easy to program, has been iterative rather than completely revolutionary.

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ANCA Sheet Metal Solutions Launches New Thailand Facility

ANCA Sheet Metal Solutions Launches New Thailand Facility

Anca Sheet Metal Solutions has launched its new, state-of-the-art manufacturing facility in Thailand. The company offers a comprehensive set of service in the metal fabrication industry. “The business has grown significantly over the last couple of years as we gained customers in the automotive, food processing, construction and aerospace industries. We have invested in new equipment and refurbished the building to meet this growing market demand,” said Frank Holzer, ANCA Sheet Metal Solutions General Manager.

“We have taken a dynamic approach, using vibrant colours and punchy angles, to ensure we stand out immediately in the sheet metal and fabrication industry.  Having a strong brand is one of the most effective business tools you can have, and I am confident that with our new identity we will see great success. We pride ourselves on our service, quality and global network servicing customers across the world,” he continued.

The new facilities boast:

•     Qualified manufacturing engineers
•     Laser cutting
•     Waterjet cutting
•     Folding and forming equipment
•     Welding and painting
•     Assembly and testing
•     A lean manufacturing approach

 

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ANCA Motion’s New Tubular Linear Motor LinX M Series

ANCA Motion’s New Tubular Linear Motor LinX M Series

The latest addition to the LinX range continues to support demanding automation applications whilst increasing efficiency in a compact footprint. The LinX M-series linear motor features an integrated position sensor with 10 um of resolution, eliminating the need of an external encoder, simplifying the system design and reducing the overall cost. Modular design of the heatsink and end-caps enables flexibility in system integration. The motor produces a continuous force range of 90 N to 160 and a peak force range of up to 1,200 N.

The series is designed to deliver superior performance for high dynamic applications: velocity up to 10 m/s and maximum acceleration of higher than 30 G. With integrated position feedback and pneumatics compatible mounting design, the M-Series motor range is an ideal replacement to pneumatic cylinders also simplifying system integration, commission and maintenance. When compared with a pneumatic system the LinX motor offers a reduction in operating costs due to reduced energy consumption and maintenance.

Naveen Nadesan, Global Marketing Manager said: “With a fully potted motor body and sealed stainless steel shaft, IP67 protection level can be achieved by the motor, making it ideal for food and beverage packaging applications. Automation is advancing at a dramatic pace and that is good news for manufacturers. The buzz of Smart Factories and Industry 4.0 isn’t just noise as automation drives efficiencies, reduces cost and improves quality. This latest product by ANCA Motion has been designed to offer manufacturers a better solution than what was previously available and our linear motor technology has proven success in the market place with customers raving about the improved performance of their machines.”

“For example, an Australian customer Sutton Tools reported a 10 percent improvement on its surface finish on their tools after moving to a machine using the linear motor. This change was achieved by moving away from the traditional ball-screw movement on machines to a linear motor and we have taken this technology and extended its capabilities so that more manufacturers can benefit,” Naveen concluded.

Jeff Boyd, Export Manager at Sutton Tools said: “By really focusing on how we could improve the surface finish, and with the added capabilities of the linear motor, we have created a product that is delivering significant productivity gains for our customers. The team are now consistently achieving a longer tool life and faster cycle times in the machining of the higher strength materials such as titanium and inconels which is a great result.”

The LinX motor design itself improves machine life and reduces wear on guide ways or rails, eliminating the downforce associated with flatbed motors due to the zero net attractive forces.  The magnets contained within the LinX motor stainless steel cylinder allow machine builders to align the motor with much more ease, meaning machines can be built faster and safer.

LinX M-series Linear Motor has been designed in a variety of different sizes to allow for application-specific solutions.

 

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Better Surface Finish With Linear Technology

Better Surface Finish With Linear Technology

To gain traction in the aerospace industry, Australian manufacturer of rotary shank cutting tools, Sutton Tools, has been using linear motor technology. Article by Anca.

Jeff Boyd, export manager at Sutton Tools said, “By really focusing on how we could improve the surface finish, and with the added capabilities of the linear motor, we have created a product that is delivering significant productivity gains for our customers. The team is now consistently achieving a longer tool life and faster cycle times in some of the higher strength materials such as titanium.”

Mr Boyd added that improvements in the surface finish of the cutting tools have been achieved by moving away from the traditional ball-screw movement on machines to a linear motor. The company also conducted a direct comparison and experimented with different grinding wheel grades and grinding parameters for the best finish.

“A better surface finish has also mean we get better adhesion of the coating and stable performance to the cutting tool which is important for our customers. Tool stability is important because it means our customers can confidently forecast their production schedules and reduce machine down time,” said Mr Boyd.

In order to validate their grinding methods, an optical 3D scanning technique is used to measure the area surface roughness on the rake face and the cutting rake on the tools.

Anca has combined linear motion motor technology from its sister company Anca Motion to its own rigid grinding machines. The LinX cylindrical linear motors prevent loss of preload or rigidity when grinding tools and reversal errors are eliminated and higher contouring accuracy can be maintained due to a unique control algorithm.

Global Linear Motion Systems

According to Market Research Future, the global linear motion systems market is expected to touch a whopping US$8.76 billion mark at a staggering CAGR of 7.8 percent during the assessment period (2017-2023). Various technological advents across the industrial spectrum have given rise to the need for a linear motion system (LMS) to enhance the operational process by having a continuous transfer of products.

With industrialisation on the rise and people having more disposable income in their hand than before, segments such as automotive, food & beverage, packaging, healthcare, manufacturing and others are getting an unprecedented boost. Seamless processing, agility, efficiency in handling shock load condition, and safeguarding against contamination and moisture have made it the foremost procedure for several industrial verticals.

Automotive industry demands an operational technology which can deliver round-the-clock service of the highest level of accuracy without any variance. LMS fits the bill perfectly. Furthermore, advantages such as low maintenance cost and cost-effective production capability have helped it emerge as peerless industrial technology. Its compact size and load capacity help it attain versatility where it gets involved in productions of specialized vehicles such as ambulance, professional vehicles, fire trucks, telescoping trailers, and vehicles for disabled people.

However, lack of product variance can impede the growth rate during the forecast period. Market competitors are offering LMS at an affordable price, but the option remains very limited for the consumers.

Industry Trends

Minimal errors and accurate positioning of equipment have made LMS a market rage in the healthcare sector. Its easy maintenance has been accepted widely across verticals. Features accounting for its high demand are hygiene standards, high performance, and durability of devices.

The market leaders are trying to customize it according to the needs of the industry. Thomson Industries, Inc., has recently introduced T-Cas Linear Race Shafting that provides various benefits to automation manufacturers and can be considered exemplary.

LMS is currently penetrating other markets such as wastewater management, shale gas exploration, and aerospace & defence. An exponential rise in the use of LMS can be seen in these sectors.

Segmentation

The global market of LMS can be segmented based on type and application. Type-wise segmentation includes single-axis linear motion system and multi-axis linear motion system. Multi-axis linear motion system is leading the market and expects to grow at a rapid CAGR of 8.5 percent to reach a staggering US$5.70 billion mark during the prognosis period. Compared to single-axis, multi-axis is cost effective and can perform in diverse industrial platforms.

Application-based segmentation comprises packaging, machine tools, palletising, robotics, material handling equipment and others. Machine tools dominate the market and are expected to do so during the assessment period with the fastest CAGR of 7.7 percent. The segment stands out owing to its requirement of high accuracy control. LMS also betters the efficiency of machine tools by implementing innovations and solutions. In doing so, LMS has become the favourite of the machine tools segment.

Regional Analysis

APAC dominates the market and generates the maximum market revenue. China leads the region by making US$807.4 million in 2017 and is projected to grow with an impressive 11.1 percent CAGR during the forecast period. Japan and India follow the line. The presence of major sectors has boosted the semiconductor demand in the region owing to which the market is witnessing such growth.

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Creating New Opportunities With Cloud Computing

Creating New Opportunities With Cloud Computing

What are some key concerns for adopting cloud computing platforms for manufacturers? By Thomson Matthews, software product manager, Anca

There is lots of buzz around the cloud, a key technology driving a new era of smart manufacturing. Some potential adopters have questions about the justifications for and security issues around adoption, but these can be easily addressed.

Multidimensional Value

The cloud computing megatrend has been hard to miss for consumers or businesses. Cloud-enabled platforms have transformed everything from transportation to accommodation, and helped create some of the world’s most valuable companies. As a matter of fact, 1.65 million business people rely on cloud data day-in and day-out.

Adoption by enterprises has been swift. Technology research firm Gartner published a report in February predicting the pace of growth in public cloud services would reach its peak this year at 18 percent, with a total value of US$246.8 billion. Companies were pursuing cloud strategies, said the firm, due to the “multidimensional value of cloud services, including values such as agility, scalability, cost benefits, innovation and business growth.”

Manufacturing Adoption                                  

Despite these and other benefits, manufacturers appear to be slower adopters than those in other sectors. An Economist Intelligence Unit (EIU) report published last year notes that “manufacturing appears to have something of a late start in cloud”. Adoption, however, was predicted to increase “significantly and rapidly”. The report’s respondents predicted that this reluctance will fade, and 71 percent expected cloud would be a major factor within manufacturing in five years.

In CNC machining and other types of manufacturing, the adoption of cloud computing —collecting data from many devices at one point—will be transformative, allowing intelligent, autonomous decisions throughout supply chains.

The cloud is one of the “nine pillars” making up Industry 4.0, and critical for the “Internet of Things” trend, which McKinsey predicts will create nearly five trillion US dollars in value in business-to-business settings annually by 2025.

Benefits Of Cloud Computing

Networked production comes with a number of benefits. A connected bank of CNC grinding machines, with real-time analytics presented through a browser, enables operators to see which machine is doing what and where there might be bottlenecks.

Capacity can be optimised through floating work orders, enabling a company to get the most out of their investment and to juggle smartly.

With collected data, we can use machine learning algorithms to analyse machine performance, learn when and how a machine will fail, and trigger preventive maintenance actions before failure occurs. Downtime can be minimised, with maintenance notification software-based alerts telling an operator when there is a problem and allowing them to intervene early. Predictive rather than reactive maintenance brings obvious benefits.

Cloud-based communications can help alleviate the burden by eliminating maintenance, IT workload, and some of the costlier internal infrastructure, including servers and storage systems. Manufacturers do not have to worry about data backup in case of system failure and power consumption can also be cut.

Debunking Myths

There are some enduring negative ideas that are inhibiting cloud adoption in manufacturing.

Intellectual property security is high on this list. However, it is easy to get alerts in cloud systems on potentially problematic activity based on behavioural analysis, for example if a worker is attempting a forbidden download from a machine.

Secondly, cloud vendors provide data centre-grade security to customers. The credibility of a company like Amazon as a vendor depends on—among other things—the integrity of data security they can provide. Also, if you already share workplace data using, for example, Dropbox, then guess what? You are already using a cloud service.

There might also be concerns around viruses, though this should not be a problem where there are only outbound flows of data.

Another reservation might be around cloud or vendor exit strategies. Both will be clearly covered in the terms and conditions when subscribing to a new service. Cloud offering from companies such as Anca, for example, allows customers to export data at any time from on-premise to cloud or vice-versa.

Many of the concerns around using IoT cloud services have been seen previously in the world of cloud-based mechanical computer-aided design (MCAD) software, and these have faded over time. Nowadays, offering MCAD in the cloud is pretty much essential for vendors, and it has driven benefits to customers including but not limited to performance, scalability, and cost.

Making Informed Decisions

The value of cloud-based connectivity on the factory floor will continue to grow as the Industry 4.0 movement accelerates. Right now, users can immediately gain from better planning, based on informed decisions, based on data.

The EIU report mentioned above cites three waves of adoption for transformative technologies.

First comes cost reduction. Then there is doing what has been done now, better.

The third wave, though, “is the most fascinating—the creation of unforeseen, wholly new opportunities that no one planned for or expected.”

 

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Anca: FCP4 Drill Grinder

Anca: FCP4 Drill Grinder

Anca’s FCP4 Drill Grinder can produce drills from 0.8 to 4 mm on a single machine. From a high speed steel blank, the machine grinds the flute, relief and point producing a finished drill. It has grinding and dressing operations with the company’s Motion CNC and drive technology. The flute shape is adjusted by CNC and form dressed on the machine.

With an enclosed machine canopy with safety interlocks and an operator panel with touch screen, a complete drill can be being manufactured every 20 to 25 seconds.

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