The latest manufacturing technologies highlighted and some released at the recent EMO Hannover 2023.

Leading supplier of machine tool, tooling, consumables, services and accessories supplier to the metalworking and related engineering industries, the Retecon Group, has highlighted a number of new products recently released by the companies that they represent in South Africa. Some were launched at the EMO Hannover 2023 exhibition held in September 2023.

Retecon has serviced all the metal forming and cutting disciplines including milling, turning, gear cutting, boring, grinding, tube and wire, EDM, pressing, punching, laser, bending and measuring for 53 years by importing quality well-known brands from all over the world.

Retecon’s various products range from vertical and horizontal machining, turning lathes, multi-spindle lathes, universal milling and boring, tool and cutter grinding, laser cutting systems, bending systems, punching and forming machines, automatic sawing equipment, roll forming, wire and tube cutting and bending machinery, measuring equipment, fixtures and fittings, manufacturing lines and much more.

The Retecon Group represents a number of well-known international manufacturers including Trumpf, United Grinding-Studer-Jung-Mikrosa, GF Machining Solutions, Kasto, DMG MORI, Ficep, Kapp-Niles, Hexagon Metrology Group, Schuler, Renishaw, Leica, Mahr and EFD.

DMG MORI
DMG MORI exhibited in their customary Hall 2 occupying 9 000m² and themed DMG MORI City. Guests could see holistic production concepts and state-of-the-art machine tools in all fields of technology – from universal and production turning to 5-axis machining centers and turn and mill centers to additive manufacturing.

Machining Transformation (MX): Holistic approach to manufacturing technology
Every company must face up to the challenges of increasingly efficient and sustainable manufacturing. DMG MORI supports its customers in this with Machining Transformation (MX). The new concept was presented at EMO. It combines the four pillars of process integration, automation, digital transformation (DX) and green transformation (GX) for modern and sustainable manufacturing.

With over 36 full machining centers on display, the latest in DMG MORI’s Machining Transformation – from additive/subtractive hybrid machines, world premieres of horizontal 5-axis mill/turn machines, fully-automated robotic tending with ARVs and more were on display.

Among the 39 machines and 20 automation solutions are world premieres such as the CTX beta 450 TC turn and mill center, the CTX 450 and CTX 550 universal lathes, and the INH 63, a horizontal 5-axis machining center. The new automation solutions – the PH Cell 800 pallet handling system and the UH-AMR 2000, an autonomous robot for material and tool handling, completed the portfolio.

With a footprint of just 10m², the CTX beta 450 TC marks the new entry into the series of high-tech turn and mill centers from DMG MORI. The work area offers space for workpieces with diameters of up to ø 500mm and lengths of up to 1 100mm. The bar capacity is ø 76mm or optionally ø 102mm. The heart of the new model is once again the compactMASTER turn and mill spindle with a speed of
15 000rpm as standard and 20 000rpm as an option. The speed of the main and counter spindles is a maximum of 5 000rpm or a torque of up to 720Nm.

The DMG MORI Trade Fair Events App turned visitors into interactive participants by allowing them to interact digitally with the machine tool manufacturer. App users benefited from more information during their visit to the trade fair and they can continue to use it afterward.

The app offered a detailed hall map, registration for guided tours, further information, and brochures. Using QR codes, visitors can transfer all valuable information (e.g. on a machine) directly to their smartphone and retrieve it at any time.

Renishaw
Renishaw has provided manufacturing technologies for machine tools, CMMs and other machines to all industries for 50 years. Renishaw’s solutions help companies around the world to operate more productive and sustainable manufacturing.

Renishaw showcased a range of new products that deliver improved performance accuracy and repeatability, including the RMP24-micro – the smallest wireless machine tool probe on the market, measuring just 24mm in diameter and 31.4mm in length.

As well as its miniature size, the RMP24-micro also delivers market-leading metrology performance for a wireless probe in this size category. With measurement repeatability of 0.35 micron 2σ and low trigger forces, it is ideally suited to compact machines manufacturing high-value, high-precision components, such as those found in the medical, watchmaking and micro-mechanics industries.

RMP24-micro utilises Renishaw’s updated radio transmission protocol to communicate with the machine tool controller – via the RMI-QE radio interface. With an operating range of up to 5 metres, it employs a 2.4 GHz frequency hopping spread spectrum (FHSS) protocol, which is industry-proven and compliant with radio regulations worldwide. FHSS technology enables both the probe and interface to jump from channel-to-channel while maintaining communication, allowing the probing system to operate alongside other radio sources such as Wi-Fi, Bluetooth® and microwaves. This is not the case for other protocols which may require manual intervention to operate in the same environment.

Heller
At the heart of Heller’s stand at EMO 2023 was the 360° Performance – a holistic view of the demands placed on modern production. To meet these demands, Heller focused on five solution areas. In addition to the F 6000 5-axis machining center from the latest generation of the F series, Heller presented products for the digitalisation and automation of production, a comprehensive range of services as well as innovative manufacturing processes and technologies for complete machining on a single machine.

The 5-axis machining centre F 6000
The 5-axis machine with head kinematics is designed from the ground up for flexible, powerful series production. Like all Heller machines, it sets a benchmark for cutting performance and precision. Highlights include free chip fall, short idle times, optimum automation capability and compatibility with the H and FP series for a wide range of workpieces. The F 6000 also boasts first-class equipment, a small footprint with a width of 3.70m and expandability with technologies such as Mill-Turn, interpolation turning or power skiving. For combined milling and turning operations, the machine is equipped with the optional Mill-Turn function, in which the high-torque DDT (Direct Drive Turning) rotary table with speeds up to 700rpm plays a key role.

Automation solutions
On show was the Heller RSP 12H6 rotary pallet storage. With a total of 11 pallet storage locations as standard, the automation solution enables flexible and automated handling of machine pallets and is predestined for series production of small and medium batch sizes. A third level can be added to extend the solution to up to 17 storage locations plus loading station. Augmented Reality was used on the booth to demonstrate its functionality and expandability.

The RZ50 robot cell from the Heller automation portfolio also provides an insight into flexible robot automation for automatic loading and unloading of workpieces, fixtures and pallets, as well as the automation of other handling tasks.

At the show, Heller will also be presenting the Automation Calculator. It allows users to enter workpiece data, production information or the desired machine into a touch-enabled terminal and then receive recommendations on the most suitable automation solution and the associated payback time.

Fit for the factory of the future – digitalisation
With a new intuitive operating concept, the Heller Services Interface ensures transparency in manufacturing, maintenance and service processes throughout the entire lifecycle of the machine. This option can also help reduce machine downtime by providing evaluations and statistics. Visualisation of specific machine status information, including status indicators for axes, spindles or other assemblies, enables users to determine the wear status and take preventive action to reduce unplanned downtime.

Mike Lee of Retecon with Titan Gilroy of Titans of CNC: Academy and Titan’s son Tyson. Heller Machine Tools has a strategic partnership with Titans of CNC, Inc, which was announced in September 2022

Ficep XBLADE CNC line for drilling, tapping, milling and sawing
The new Ficep XBLADE CNC line for drilling, tapping, milling and sawing with disc blade is capable of processing steel construction beams of different sizes, with sections up to 305mm by 305mm on three sides, 450mm by 450mm on one side and variable lengths thanks to its modular configuration. The XBLADE CNC line is a “universal” machine lending itself also to the machining of light alloy profiles.

The innovative feature of this machine is the ability to perform 3-axis machining even on inclined planes, in two different directions. The 5-axis head consisting of two rotating wrists positions the tool virtually anywhere in the working space. In addition, the introduction of the disc blade expands the range of processing that can be carried out without manual intervention. The integration of the blade with the 5-axis head makes it possible to work around the workpiece by intervening on 5 faces.

The machine tool changer system has eight positions with standard tools, two positions for large tools and one position for the 560mm disc blade.

Hexagon
In addition to their total manufacturing solution, Hexagon exhibited the following product highlights from the field of production measurement technology:

Measuring in the machine tool with Hexagon multi-sensor technology
Hexagon’s unique laser scanning and ultrasonic measurement, measurement and automation solutions offer you greater safety, higher quality and increased productivity in your manufacturing process.

Etalon machine calibration and optimisation
Hexagon’s Etalon machine calibration and optimisation programme provides system solutions for accurate and comprehensive geometric analysis, improved monitoring and accuracy of machine tools, measuring machines, robots and structures.

Global S
A universal coordinate measuring machine that gives you accurate measurements helping to increase quality and minimise scrap.

OPTIV
Multi-sensor measurement solutions that combine tactile and optical sensor technologies in one device, enabling efficient monitoring of your manufacturing processes.

Leica Absolute Tracker AT960 and AT500
Mobile measuring devices that enable fast and accurate measurement of large components, increasing efficiency.

Absolute arm
Portable coordinate measurement solutions that enable you to measure accurately in a variety of environments. The Absolute Scanner AS1-XL is built using the same ‘shine’ technology as its flagship Absolute Scanner AS1, allowing it to collect extremely clean 3D data at very high speeds from challenging surfaces.

Studer
At this year’s EMO, grinding machine specialist Studer presented a new automation solution on the United Grinding Group stand. Swiss-based Fritz Studer AG, is a market and technology leader in universal, external, internal cylindrical, and non-circular grinding. The new automation solution on display was attached to one of the company’s S31 universal external cylindrical grinding machines.

Other Studer models on display included the favorit, the S33 with uniLoad automation, the S100, an ergonomic entry level machine, and the S131R with roboLoad, a highly flexible machine for every conceivable internal grinding task.

Also on show was the Customer Oriented Revolution (C.O.R.E.) control, being introduced across all United Grinding Group brands. The advanced hardware and software architecture on which C.O.R.E. is based enables an innovative machine/operator interaction concept. United Grinding says C.O.R.E. is much more than just an operating system. It enables new possibilities for networking, controlling, monitoring and optimising the production process. It also lays the foundation for the operation of modern Internet of Things (IoT) applications further opening the door to a digital future in manufacturing.

ViciVision Prima simplifies optical measurement for turned parts
ViciVision’s Prima optical measurement series for turned parts is designed to simplify measurement. The company says it reduces programming learning time by 30%. It is also designed to transform part measurement by providing a more objective measurement system. The Prima optical measuring machines can streamline the process by simplifying steps, with no need for an operator manual. It features “Vivian,” a programming assistant to guide users step by step through the measurement process.

ViciVision also designs, manufactures and distributes a variety of other optical measuring machines for turned and ground parts. With these non-contact instruments, it is possible to take many measurements in a matter of seconds, such as static, geometric, thread, form or nut measurements.

GF Machining Solutions CUT F 600 wire EDM eliminates wire breakage
GF Machining Solutions has launched the CUT F 600 wire EDM, which includes the company’s Uniqua control, Intelligent Spark Protection System (ISPS), iWire intelligent functions, and RFID Smart Wire system. Design enhancements help with thermal stabilisation, vibration control, and machine movement precision, the company states. The machine’s HMI has a 19-inch vertical touch screen, a full keyboard, and mouse.

The iWire function automatically identifies and adapts the wire speed to changing erosion height conditions during the wire EDM process. This capability eliminates wire breakage while reducing overall wire consumption per job. It works in tandem with the ISPS.

This functionality recognises where the sparks are happening during the process. It also measures and identifies the position of each spark along the length of the EDM’s wire. Knowing the exact location of a spark allows iWire to automatically adapt the wire spool speed accordingly.

The AgieCharmilles CUT E Series puts efficiency at the touch of your finger with a smart, easy-to-use human-machine interface (HMI) and onboard technologies that streamline your job setup. Thanks to the digital Intelligent Power Generator (IPG), cutting speed and surface finish are improved.

Trumpf
Trumpf is poised to launch its TruMatic 5000 manufacturing cell with the new SheetMaster at Blechexpo in Stuttgart. Users of the new system will benefit from fully automated laser-cutting, punching and forming capabilities. The new SheetMaster enables a fully automated flow of materials within the manufacturing cell – from loading and unloading the machine to removing finished parts.

“The TruMatic 5000 is yet another example of Trumpf’s market-leading position in the field of connected manufacturing. This solution is designed to be seamlessly integrated in a self-contained smart factory, giving users efficiency gains along the entire process chain,” says Trumpf product manager Steffen Wagner. Trumpf’s new machine is equipped with a six-kilowatt fiber laser to maximise productivity. As well as saving energy, this laser also does an impressively fast job of cutting sheet-metal parts. The system comes with a descending die that prevents parts from being scratched during the punching process. The TruMatic 5000 punching head also comes with a patented Trumpf electric drive known as the DeltaDrive, which uses around 30 per cent less energy.

Trumpf has fully automated the material flow in the TruMatic 5000. This improvement was made possible by the new SheetMaster technology, which uses grippers to handle parts in the manufacturing cell. The suction cups on the new SheetMaster’s grippers are monitored by sensors and can be activated individually. This makes gripper operation even more flexible, speeding up workpiece handling and saving valuable time, especially for smaller batches. In addition, the SheetMaster can be connected to an automated STOPA storage system which automatically supplies the manufacturing cell with raw material.

Haimer Microset Uno Autofocus minimises machine idle time
The Haimer Microset Uno Autofocus tool presetter automatically focuses on cutting edges so they can be measured quickly by the operator. This machine minimises incorrect data inputs, since it locates the edge with only one push of a button. The Uno Autofocus includes motorised spindles with a convenient cabinet and a 23”, 10-point touch screen. The company states that the machine will save machinists money through minimising machine tool setup time.

For more information contact Retecon Machine Tools on TEL: 011 976 8600 or visit www.retecon.co.za