How can you transform a high-speed milling machine for dental products into a high-performance automatic machining system for the automotive industry? The Göttingen-based mechanical engineering company Akcurate & CIMT took up the challenge and solved it with a complete solution from Bosch Rexroth.
What do dental implant products and body parts have in common? Both products place extremely high demands on precision and economy, and high-performance machines can now be found in Göttingen that meet these requirements. Measuring machines and high-speed milling machines manufactured by Akcurate & CIMT are used in the medical and dental sectors as well as in the automotive and aerospace industries. The machine builder can not only integrate additional functions such as measuring, turning, tightening and robotic automation into the machine, but also use its cross-industry expertise for innovative projects. One of the projects is the further development of existing dental machines for the mass production of body parts.
Further development of dental milling machines
The unusual project concept came from an automotive supplier. The supplier was looking for a robust, fully automated, high-speed milling machine for machining high-strength steel and aluminum tubes. Andreas Kirsch, Managing Director of Akcurate & CIMT, recalls: "We initially chose a high-performance machine for use in the dental industry and then considered how we could further develop it for use in the automotive industry. It soon became clear that our project needed to find an integration partner to be successful. With this in mind, we decided to involve our long-term partner Bosch Rexroth. It provides relevant application knowledge and the necessary best-in-class components, all from a single source. “
High-speed machining that is transparent and visible
Unlike the small blanks for dental implant products, the Akcurate Pi5 Tube, developed with the help of Bosch Rexroth, can now process tubes up to 7 meters in length, which are automatically loaded and unloaded by three cobots.
The linear feed axis moves the workpiece into the milling machine, cuts it into 70 cm segments, and then mills and drills as required. The fast 5-axis machining process is simulated in real time and displayed on the screen, so that the entire process is always clearly understood, even if the machine window is obscured by coolant or chips. If necessary, the operator can intervene immediately.
A range of automated services from the same brand
As soon as Kirsch came up with their idea, it immediately caught the attention of the application experts at Bosch Rexroth. Nina Heckt, Customer Development Manager, said: "We particularly enjoy this exciting project because it allows us to take full advantage of our comprehensive automation solution. With highly integrated standard modules, we are able to create a new generation of future machines that meet all requirements in terms of quality, performance and connectivity. ”
For the basic structure of the machine, Bosch Rexroth supplied a complete assembly system, including the matching feed shaft, control cabinet and front base. The complete mechanical system, including the ball screw assembly and the roller guide system, is part of the Linear Motion Technology product family. The overall solution includes not only the spindle motor, but also the drive and control system (including controller and converter).
The Pi5 Tube is controlled by the high-performance IndraMotion MTX advanced system. Industrial PCs and operator terminals are also produced by Bosch Rexroth. The experts have added a range of automated features to the HMI software for dental machines. Andreas Kirsch: "The new interface is ideally suited to the needs of future operators. With real-time visualization, everyone can get what they need. ”
ctrlX AUTOMATION will be the main platform for future use
With the new high-speed milling machine, Akcurate is also opening the door to the smart factory. The machine builder has already used the new automation system platform ctrlX AUTOMATION from Bosch Rexroth in certain areas. The modules used in the initial development phase cover a range of areas, including cybersecurity: proprietary software with a firewall runs on the control hardware ctrlX CORE to prevent hacking and unauthorized access. Akcurate is also planning to use predictive maintenance applications based on ctrlX AUTOMATION and OPC UA. In addition to allowing for continuous improvement, the big data analysis involved will help determine the necessary service intervals and extend the service life of machines and systems. Andreas Kirsch explains: "We want to get the most out of ctrlX AUTOMATION over time while continuing to use other applications. In the near future, we want to provide remote support through the application layer in order to save time and money for us and our customers. ”
Faster and takes up less space than laser cutters
As the development work progressed, Akcurate introduced a machine with a high degree of automation, which resulted in a significant increase in productivity. With a cycle time of around 20 seconds, which is even better than benchmark laser cutters, even aluminium extruded profiles can be machined with precision, without burrs and without the need for liquids. As Kirsch points out, the new system takes up only one-tenth of the space it normally would. Kirsch: "Together with our partner Bosch Rexroth, we have achieved real innovations in the field of automotive engineering and body construction. This new machine is sure to attract a high level of attention from competitors. ”
Source: Bosch Rexroth
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