Transfer Real Data
ANCA provides a standardized interface in the WheelEditor of ANCA’s own ToolRoom grinding software, which enables both the export of wheel information and the import of measurement results. These measurement results are the basis for all calculations that lead to a perfect tool in the first run.
Optimal Interfaces
It does not matter whether the wheel data is managed locally or across multiple machines using ANCA WheelServer. This interface can be used to exchange all wheel information, such as diameter, wheel radius, wheel angle, flange size and other relevant information. The interface also offers the option of exchanging only individual parameters, such as flange size or diameter, for wear control. In this case, only this data is transferred via the network and measured. The results are also provided and transferred via the network.
Enormous Time Savings
FRAISA, a precision tool company based in Willich, Germany, uses the ZOLLER »venturion« premium presetting and measuring system to measure its grinding wheel packages. The data is sent directly to the ANCA WheelServer, which assigns the actual data of the physical package to the virtual package and in turn provides this to the grinding machine. “The transfer of actual data from the ZOLLER device to the ANCA software is a game changer for us. It saves us an enormous amount of time and effort,” says Stefan Schaefers, Head of Technology at FRAISA. Here, each package is measured before use, ensuring that only real data is used.
Impressive Progress
Since its introduction in 2018, the system has been implemented on all ZOLLER devices and the 20 ANCA machines on site. “We are talking about 10 grinding wheel packages per day that are dressed by our external partners and then measured directly by the machine operators in our company,” explains Schaefers. The results are impressive: “Particularly with regard to machine availability, external measurement and automated data transfer have brought huge improvements. We were quite amazed ourselves when we did the first evaluations in this regard and realized that we could save 20% in non-productive time and reduce the rework rate by 10%."
High Plant Efficiency
FRAISA GmbH in Willich is the main location for tool reconditioning at FRAISA. Around 350,000 tools are reground here every year. The ReTool® concept uses the latest production control and automation solutions to offer customers cost savings of up to 70 % compared to new tools, while also reducing CO2 emissions by 50%. This is possible, among other things, due to a very high level of plant efficiency, which in turn is partly due to grinding wheel management. “Our motto is ‘first tool = good tool’,” says Schaefers. “This only works if we do our homework in terms of data storage, measurement and handling. Thanks to the data transfer between ZOLLER and ANCA, we always have a ready-to-grind wheel package at hand. The error rate is practically zero due to the guaranteed repeatability and operator-independent measurement. If the wheel pack fits, the tool is as good as in the simulation after the first regrind."
No Typing Errors
Steffen Kluth, Product Manager for Digital Manufacturing at ANCA, adds: “The measurement on the ZOLLER and the data transfer to the ANCA machine can be carried out by the machine operators. These are value-adding tasks that have a significant influence on quality and thus also increase the value of daily work. In addition, data transfer eliminates the risk of typing errors.”
Integrated Manufacturing
The state-of-the-art production methods and control at FRAISA are success factors for ReTool®. Schaefers sees this advantage and has already thought about further enhancements. “We are aware that the use of connectivity and automation must be continuously expanded. For example, we want to become even better at grinding wheel management. We have 250 different variants of grinding wheel packs in circulation. On the one hand, we have to maximize the efficiency of our workflows and, on the other hand, we have to ensure that we always have a duplicate wheel pack available when one is needed. That’s another thing we’re pushing.” “That’s a further important step towards the integrated manufacturing of tools,” says Kluth, “because the data format used for the transfer is based on the widely known XML format.“
Digital Tool Production
This standard will also be incorporated into the future specification OPC UA for Cutting Tools, for example. Since the introduction of its own modular automation system AIMS 2022, ANCA has developed its own portfolio for digital, automated tool production further and is also contributing to various standardization projects, such as the GDX interface or umati.
Cutting-Edge Technology for Maximum Precision
FRAISA produces high-performance tools for metalworking and is one of the leading manufacturers in the machining industry. With around 545 employees, we operate at seven locations worldwide. Since its foundation in 1934, FRAISA has stood for the highest technological standards, creative engineering, quality and teamwork. FRAISA SA in Bellach (Switzerland) has been the main registered office of the company since it was founded, with the production facilities for all milling, drilling and thread cutting tools. The workforce of FRAISA GmbH, based in Willich, central Germany, takes care of customers and distribution partners in the German market. In addition, more than half of the employees carry out industrial tool reconditioning work under the mantle of the company’s FRAISA ReTool® service. For this purpose, FRAISA’s production shop is equipped with state-of-the-art CNC grinding centers and systems for cutting-edge conditioning and carbide coating.
Product Finder