Machine tools are the foundation of manufacturing, which utilize computer numeric control (CNC) to control tools such as lathes, mills, and drills for automated, high-precision processing of parts and materials. In recent years, the trends of smart manufacturing and AI development have started to require machine tools to be equipped with the capabilities of auto-tuning, automated diagnostics, and integrating with peripherals. Beyond that, the demands for IT and OT integration, predictive maintenance, digital twin and carbon reduction are also gaining increased attention.
Still, many factories rely on experienced workers to tune and operate machine tools. "From interpreting blueprints, setting parameters, to programming, each step of tool operation requires deep knowledge gained over many years," says Yuanming Liu, the manager of the CNC Product Section of Industry System Development, IABG, Delta. As the industry continues to pursue higher precision, speeds and low-volume high-variety production, human intervention becomes a source of uncertainties.
Another pain point comes from the machine itself, in which the system integration has to meet the needs of smart upgrades. For example, integrating product design (i.e. CAD/CAM) into the machine tool could well optimize processing efficiency. To further achieve line automation, the machine tool may even incorporate the scheduling and labeling software, and machine tending robot. On the management side, connection to the ERP / MES and factory management systems are critical steps to enhance overall production efficiency.
CNC Controller Tailored for Industry Needs
Having observed the industry pain points in machining and digitalization, Delta has developed solutions leveraging its comprehensive portfolio from drives, servo systems, and controllers to IIoT and smart management platforms. The solutions center around the Delta CNC Controller NC5, whose multi-core architecture provides excellent computing power with system flexibility and connectivity to deliver high-quality performance. For instance, Delta’s Milling Machine Control Solution not only enables fast and precise processing with a smooth finish, but also integrates the CAD/CAM software into the NC5 Controller to enable path and interference simulation, which effectively reduces errors and losses.
Mobilizing AI technologies, the NC5 Controller can automatically identify features from DXF files, select tools, and auto-generate paths to reduce the operation threshold. Additionally, in the case of machine failure, the operation records can be sent to the OEM manufacturer for precise diagnosis and faster troubleshooting. The NC5 Controller’s guided UI makes the operation even friendlier.
Delta’s strength lies in its comprehensive portfolio ranging from controllers, drives, and motors, which allows it to tailor solutions to fit industry needs. In addition, Delta’s component products can execute unique optimization commands to achieve smoother operations that cannot be matched by mixing products from different manufacturers. Delta’s solutions also offer flexibility to better fit the needs of different applications. For example, the NC5 Controller pairs with different sizes of screens to satisfy the needs of specialized machining such as woodworking. The balance of system integration and flexibility allows Delta to deliver tailored solutions for specialized tool positions and processing requirements. So far, our solutions cover lathes, milling machines, grinding machines, aluminum profiling, woodworking, luggage, and thermos bottle applications, which are all ready for deployment.
Smart Upgrades with IIoT and AI Technologies
Building on the foundation of system integration, Liu points out, machine tool manufacturers can leverage Delta's digital twin, IoT, and AI technologies to develop a smart manufacturing factory. For example, Delta's Equipment IoT Platform DIALink, which supports protocols such as OPCUA and MQTT, can connect the NC5 Controller, the High-End Servo System ASDA-A3, the Power Meter DPM, robots and different machines to achieve real-time monitoring of production lines. It also connects the automated production lines with the MES system, while centralizing management of process codes and diagrams. These features effectively reduce errors and losses, and improve overall efficiency and output.
Smart manufacturing is also key to sustainability. In addition to driving energy efficiency with optimized path, parameters and spindle speeds, Delta’s smart solution can achieve holistic factory management for efficient resource allocation. The NC5 Controller can access the operating status of components to enable real-time management and adjustment of equipment strategies. This allows efficient production resources planning across the entire factory. The data collected from smart meters is uploaded to the NC5 Controller to calculate carbon emissions during the machining process. Energy consumption information can also be uploaded to DIALink for centralized management and optimization of production decisions.
Delta's Smart Solutions for Machine Tools provide the following benefits:
- Tailored for Industry Needs with Convenient Operation
The Delta CNC Controller NC5 can integrate CAD/CAM to simulate paths and interference before processing, and leverage AI technologies to auto-identify features of the product design through imported DXF files. Based on the results, the NC5 Controller selects tools and auto-generates paths, which reduces programming needs. In the case of machine failures, operation records are sent back to the OEM to troubleshoot faster and more accurately. Delta’s total solutions enable smooth machining with a higher degree of integration while allowing the flexibility to cater for specialized machines such as woodworking.
- Holistic Smart Management with IIoT Connectivity
Delta offers smart solutions with technologies such as digital twin, IIoT, and AI to build an intelligent factory. Delta's Equipment IoT Platform DIALink connects the NC5 Controller and components to monitor the production line in real time. Delta can also build automated production lines by integrating equipment, robots and even the MES system.
- High Performance and Energy Efficiency to Strengthen Competitiveness
Delta improves energy efficiency first by optimizing paths, conditions, and spindle speeds control. The NC5 Controller also collects the operating status of components to adjust equipment and resources management in time. The energy consumption data collected from the smart meter can be calculated by the NC5 Controller for carbon emissions, which can be saved for traceability.
Delta’s Smart Machine Tool Solutions are designed for industry needs as well as to lower the threshold of machine operation with a friendly interface. With energy consumption and carbon emissions calculation and storage features these solutions allow a more sustainable manufacturing.