Anyone thinking about automation is quickly seduced by fancy robotic arms, attractive pallet systems and trendy self-driving vehicles. Far less obvious than all this moving hardware, but perhaps even more interesting to consider are new software solutions. Mazak's Smooth Ai controller is one such that is already making a difference in the market. After all, this solution makes programming easier and faster.
Although developments in the machine field are far from stalled, Mazak says the biggest innovations today are to be found in software. Sales manager Benelux Hugo Verlaak: "Our clients can achieve higher productivity by investing in automation and digitalization. The productivity gain you realize with a new machine that is just slightly faster than the previous model is negligible. The goal is to run that spindle 24/7. Only then is real productivity improvement possible. Manufacturing companies can only achieve this with automation and software solutions."
Smooth Ai from Mazak is one such solution. CNC technology can use data and artificial intelligence to help the manufacturing sector solve common problems. These include human and skills shortages, increasingly rapid new product introductions and maintaining product quality, productivity and profitability. One new functionality in Smooth Ai that can solve the skills shortage is Solid Mazatrol. Mazak developed this feature to simplify and speed up the programming of relatively complex workpieces. With Solid Mazatrol, programs can be automatically generated from 3D models, using artificial intelligence to intuitively learn and understand the cutting strategies used by the manufacturer. This can reduce programming time by as much as 90%, according to Mazak.
Solid Mazatrol is the advanced brother of Mazak's 3D Assist feature and is suitable for programming Integrex machines , CNC turning centers and three-axis machining centers. After loading a STEP file, 3D Assist helps users manually transfer all coordinates to the program. Solid Mazatrol does this fully automatically. In just five steps, users can program a product from a Solid or a STEP file. The software guides the user through the various steps in a user-friendly manner. If 2.5D machining is involved, an additional step is added; the selection of the workpiece clamp. In addition, Solid Mazatrol is self-learning. For example, if the software itself chooses to drill first and then mill, but the programmer prefers to mill first and then drill, the software adopts that strategy the next time. In this way, programming becomes increasingly efficient.
At the last EMO, Mazak already showed new features that have been added, bundled in Mazatrol DX. Especially the Quick Code function stood out. This allows you to instantly generate a quote and, after confirmation, convert it into an order and the program to control your machines. There is not much to it, for the user. He only has to enter a few parameters (material, number of parts...). The software calculates the rest, but the user has full control to change the parameters there as well (tools, fixtures, machine hours...). The result? In three minutes, the quotation for a three-axis machined workpiece is ready, as is the program. "We want to work faster and more efficiently. Especially more efficient on the front end, that evolution is coming, so that the process is completely digital," says Verlaak.
As clever as the software is, Mazak points out that expert knowledge is always needed in this type of programming. For example, with a 3 m long spindle, the system does not take into account the method of clamping to avoid vibration. The programmer will always have to take care of the clamping and positioning of the workpiece. But much of the work can be done automatically for him, so he can focus his knowledge just on those more challenging facets.
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