The intelligent machine
With a customer-oriented vision, in 2015 SORALUCE moved ahead and created a 5-year plan for the development of intelligent technologies. In addition to the technologies which have already been developed and implemented, further new developments will be presented by 2020, which will also be further leading milestones in the machine tool industry.
New developments are always made by SORALUCE with the involvement of their customers and end users. The wishes and requirements of customers have changed drastically in the last decade due to globalization and digitization. At the beginning of the millennium the focus was still on the human being with his experience, today these tasks have to be taken over by “intelligent machine” with corresponding modern technologies.
SORALUCE has already responded to the changed requirements in 2016 with its new innovative machine design. The new design concept not only convinced the clientele in terms of functionality, ergonomics and safety, but also a 41-member expert jury and won the reddot award 2016 in “functionality”.
In addition, high-tech technologies have been developed to assist the machine operators. Today, the machine “independently” takes over tasks from experienced machine operators and guarantees the safe and productive production of workpieces without the influence of the “human being”.
No more chatter!
The patented DAS+® system is certainly one of the biggest innovations of SORALUCE. It is also probably one of the most innovative technologies in the field of milling and drilling in machine tools.
No more chatter! Regardless of how it happens. DAS+® independently measures and monitors the production and the frequencies that occur during machining processes and detects vibrations right from the start. Specially developed and controlled actuators in the milling slide immediately generate counter-frequencies or counter-vibrations and also adjust the spindle speed via the SSV function.
The result is impressive.
A smooth and optimum machining process without any interventions by the machine operator.
Constant machining conditions throughout the complete working area without any influence from the machine concept. This achieves an increase in cutting performance by up to 300 % and a proven reduction in production time by 45 %.
No tool breakage
A machine operator turning the feed potentiometer, a common scene in the production. Tool breakage when entering cut on a workpiece or during with interrupted cutting conditions is now a thing of the past. With the specially developed Adaptive Control SORALUCE function, the active feed rate during milling is automatically adapted to the production situation in and on the workpiece.
By monitoring and evaluating the performance of each tool, the Adaptive Control function is an ideal supplement to DAS+®. In addition, the system more or less recognizes the material stock removal and also adapts the feed. Compared to the standard feed control possibilities of the known CNC control manufacturers, the function is also extremely useful in practice, easy to use and settings can be changed during the machining process.
Even with this technology, the advantages are obvious: Reduced processing times thanks to automatic feed control. Man-less machining through a constantly optimized machining process. No manual intervention by the machine operator using the feed potentiometer is necessary anymore. In addition, the SORALUCE machines have collision protection due to this system.
Increased tool life
Not only reduction of tool breakage but also tool life is increased up to 30 %. The production process is optimized by “DAS+®” and the integrated “SSV function” with automatic speed regulation in conjunction with the “Adaptive Control” automatic feed control. At the same time, thanks to the constant automatic optimization, the machined surface qualities achieved are permanently improved without having to invest in expensive special tools.
Simplified component setting up
The patented VSET technology from SORALUCE is a visual, automated system for measuring and aligning components. Who does not know this: Large workpieces > 1 m3 require long, time-consuming and costly alignment processes. Often enough, the alignment takes longer than the actual machining.
VSET is based on two main modules of measurement and alignment. Both modules can be used independently. The measurement of the geometry of the workpiece takes place “outside” the machine via a specially developed photogrammetry technology. In the best-fit calculation, the geometry of the component is compared with the 3D data and thus simultaneously a stock removal control to ensure the quality of the workpiece is performed. In addition, the software generates a workpiece clamping plan with detailed information with a specific reference point for the operator. The reference points are automatically measured with the machine via a touch probe.
The application and operation is simple and no experienced measurement technicians are needed. The time savings for aligning with up to 70 % is enormous and offers the customer a considerable increase in productivity of the machine.
Always high-precision workpieces
The dynamic ram balance compensation “DBS” is another patented new development from SORALUCE for optimizing machine accuracy directly during machining. At any time and without the assistance of the machine operator, the tool is set 100 % perpendicular or parallel to the machining axis. The current position of the tools is monitored via a direct integrated measuring system on the machine ram and the correction via a dynamic angle adjustment of the machine ram. The adjustment of the milling slide is made by an additional NC-axis, which is installed at the back of the machines vertical saddle slide and allows compensation in both directions regardless of the different weights of quills, milling heads and even tools. DBS provides a consistent 0.02 mm straightness of the ram axis over the full travel of up to 1,900 mm.
A machine control is only as good as the machine manufacturer uses it optimally for his machine. SORALUCE developed practice-oriented custom cycles, additional softkeys, diagnostic masks and apps for easier programming and operation of the SORALUCE machines. All of these additional control technologies have been developed in collaboration with customers’ machine operators and dramatically ease the daily production of workpieces.
In addition, SORALUCE Digital can be used to call up real-time information about the status of the machine and the current machining process. Of course, a long-term analysis with a comprehensive reporting on the current machine operation and manufacturing process to optimize the machining process and energy consumption is possible. Upon request, SORALUCE provides its customers with their own cloud system for 100 % data security.