Automation and digitization steal the show

The annual Christmas tradition par excellence? That one actually already falls at the end of November. That's when Mazak opens the doors of its showroom in Leuven. An appointment to which the sector gladly draws present. This year there were again more than 700 registrations. All those who have metal in their heart can warm themselves up to the latest technological innovations. The common thread in this year's program? How automation and digitization are gradually reaching the machine and your production processes.

Will metalworkers soon become data analysts? It won't be that fast, but that we are moving in that direction that much is certain. Even machine manufacturers like Mazak are making it happen. The platform on which Mazak's technology is built, whether for machining or laser cutting machines, has already proven its openness in recent years by being easily linked to various automation solutions. "Even with the digital data from it, work can be done. For example, by linking to customer ERP systems. But equally, the chips in tools can communicate all tool data directly with the control system. That will become more than a thing in the coming years," predicts Hugo Verlaak.

Built for operators

Mazak, of course, is also going to work with machine data itself. Every customer can register for free for iConnect: a web-based portal on your smartphone or tablet that tells you everything about your machines. Service coordinator Dirk Van Eycken: "Your entire Mazak machine park is bundled in it, neatly divided into four blocks. Under info you can find everything about the chosen options and configurations. Under manuals you can consult and download all manuals. In addition, the history of service interventions and orders is kept. You can also consult maintenance videos, find answers to frequently asked questions, and download and test run new software." A process that is not yet complete. Next year it would be expanded to include a portal for spare parts. "Mazak iConnect is really built for operators and for the maintenance crew. We provide them with all the info they need to do their job optimally."

Live monitoring

Those who want to go that step further can opt for the paid version and start monitoring their machinery live. "We place our router and customers can already get started with a secure connection. They get to see in the Mazak cloud what the machines are doing: are they working in automatic mode? Is the spindle running? What tools are on them? Are there any alarms? Information that is also logged to help companies arrive at insights into their production. Second, it helps the maintenance manager schedule maintenance services efficiently. He can generate timely alerts for the replacement of each wear part. The third asset offered by the paid version is backup, either manually or automatically. All programs and parameters are then stored in the cloud." Mazak can also, if and when the customer wants, access the machines via Teamviewer. "An ideal tool to diagnose problems correctly. After all, we get to see the inputs and outputs 100% live. If you can save two visits from a service technician this way, the investment is already more than recouped."

Gear processing

But obviously no automation and digitization without machines. Those remain the core of Mazak's business. The machine that beckoned the most curious to take a peek at the window? The Integrex i-630V AG. AG stands for Auto Gear, a variant that thus has everything needed to finish gears impeccably. "In terms of hardware (glass rulers for perfect synchronization and accuracy, adapted nozzle for chip rinsing ... ), but also in terms of software. There is no need to purchase complicated expensive additional CAM programs. Everything is present as standard to allow the machine to skive, hobbing and milling with finger milling for a straight or a bevel cut," said Verlaak. By the way, the Integrex i series, Mazak's fifth generation of multitaskers, received considerable expansion over the past year. "Users can now choose between i100, 200, 250, 350, 450 or 500," he said. Present on the show floor: the Integrex i-450 HST. "The spindle is shorter than before and more powerful, tools are now located at the rear. And through a robot, tools can also be loaded at the front. Where the number of tools used to be limited to 112, we can now go up to 250. A must for multi-batch automation."

Always accurate

Mazak also has the necessary solutions for those who like things a little more low-key. The VCN-600 is a fine example. "The VCN (500 - 600 - 700)and VCE (500 - 700) series have everything under the body that characterizes Mazak machines: speed, accuracy. The difference is in the bells and whistles on them, making them a bit more affordable, but at the same time remaining very efficient. And of course with all the possibilities for automation." The machine in the showroom features workpiece loading. "Easy to program along with the control and with a large screen to keep it visually clear for the operator," explains Verlaak. And if you still want to get more out of this and other machines, there is the Mazatrol DX software. That provides a digital transformation in the heart of production. Quicker quotation generation and automatic preparation of the corresponding machining program with only one goal in mind: to ensure that the machine can continue to work longer without loss, without errors.

Superior cutting quality

At the very back of the hall is the permanent home of Mazak's laser cutting machines. The Optiplex 3015 NEO is the same one that adorned it last year. A year without developments then? None whatsoever. A new size (4,000 x 2,000 mm) was added to meet the trend for larger plates. There is now a 20 kW laser source under the hood that, combined with Laser Beam Shaping technology, provides superior cutting quality even in 50 mm steel. But perhaps the most important development was the green next door: since September, there has been an official cooperation between Mazak and Safan Darley in the Benelux. Sales manager Benelx Laser Products Tim Depijpere: "They only have bending benches, we only have laser cutting machines. Sometimes you bump into that in the market, because some customers are looking for total solutions. So collaboration is actually a logical step, especially since we share the same DNA: we stand for quality and openness." With software an increasingly important differentiator in the market, that openness is crucial. With the Radon software from Produsoft, also present in Leuven, both machines can be controlled flawlessly. Not present, due to lack of space: the new FG-400 tube lasers. No lack of interest however. "Soon we will leave with a delegation to Japan to show the machine in all its glory. Its ability to process open or closed profiles up to 15 m with a full 3D head makes it truly unique. We are expecting something from it," concludes Depijpere.

Stronger together
As usual, Mazak was not alone during the Open House in Leuven. It also invited partners, so that visitors really get total solutions for their challenges. This year Produsoft, RoboJob, Safan Darley, Sandvik Coromant and Schunk signed on present. "A great opportunity," Werner De Ridder of Schunk calls it. The specialist in clamping and gripping was present with under his Rapido clamp change. "Clamping jaws can thus be changed in seconds, without the need for tools. A process that, by the way, is fully automatable. Everything to keep that spindle running as long as possible. An aim that you also see in the developments Mazak is presenting here."