Hurco (S E Asia) Open House: An integration between machine and robots

By: Kathryn Gerardino-Elagio

Hurco (S E Asia) Pte Ltd has organised an open house to present new technologies to its customers and to assist end-users in transforming their machine shop. Partners and visitors witnessed live demonstrations of its ProCobots -- Hurco’s take on Shopfloor automation. The event marked the launch of Hurco’s two new machines for the first time in Singapore: BX40Ui Double Column Simultaneous 5-axis machining centre and the VM15Di General Purpose machining centre.

“It has been more than four years since we had our last open house (Hurco 50th anniversary open house) so it is a good time to reconnect with our customers through this open house by presenting new technologies, understand their challenges and gather feedback on how we can continue to support their evolving machining needs,” explained General Manager Wai Yip Lee.

According to Wai Yip, this year’s open house theme is “Practical Transformation.” It starts from upgrading CNC machining capabilities; increase number of machine axis and improve clamping solutions to reduce set-up time and utilise the right cutting tools and coolant to reduce cutting time. He remarked, “When optimal machining capabilities is achieved through a review of existing processes, business owners should explore adopting suitable automation solution to solve immediate manpower issues, reduce machine idle time and maximise throughput.”

Product Highlights

The ProCobots covers a range of “1 robot to 1 machine” Profeeder systems for various parts sizes and volume. The ProCobots seeks to address the need for an automation solution that could be easily incorporated into existing machines with minimum disruption and operated by existing machinist.

Meanwhile, the BX40Ui features a ladder structure and double column design to provide maximum rigidity and outstanding support for the spindle head. The BX40Ui is equipped with a 18K rpm motorised spindle rated at 47HP and oversized linear guide rollers to tackle demanding 5-axis applications that requires accuracy, thermal stability, cutting speed and torque.

“We have specifically picked an oilwell drill bit as the demo part to showcase the superior performance of the spindle and the rigidity of the machine; how you can complete the machining of a heavy (130kg), complex part from roughing to finishing on one machine,” Wai Yip declared.

He added, “The VM15Di was introduced to fill the produce gap within our popular VM series based on feedback received from our customers. If you like our VM10i and wants a “sibling” that has a larger X-travel for a longer part or additional set-ups, faster rapid and cutting feed rates, and a faster 12k rpm inline spindle, while retaining a compact footprint, then the VM15Di will be your next upgrade.”

Moreover, Wai Yip shared that they have put up an automation cell featuring an Omron TM12 collaborative robot loading parts mounted on pallets for 2 popular Hurco CNC machines: VM10i and VM One. This automation cell provides another perspective of how Hurco machines can be incorporated into an automation cell/line. The Hurco machines are connected via ethernet to the Omron Cobot which provides enhanced flexibility in communication between machines and robot. As part of the demo, both machines were tasked to run a few CNC programs with multiple part set-ups, incorporating tool and part probing cycles in the machining cycle to provide our guests with a “close to real” automated machining cell experience.

Seamless Automated Production

Apart from selling its machining and turning centres, Hurco perceived the open house as a path to help customers ensure a seamless and automated production.

Wai Yip commented, “We aim to continue serving our customer evolving machining needs through the incorporation of automation solutions that is suitable for their machine shop setup. We hope to work closely with our customers to identify and propose the appropriate automation solution through a review of their parts, machining process, and future growth plans to achieve their desire ROI. We believe that automation need not be complicated and expensive, which is the general perception to machine shop owners. We have also invited our customers to bring in their parts for test-runs on both our automation cell and ProCobots to assess the feasibility of incorporating them into their business, and identifying training needs to upskill their workers.”

At the open house, Wai Yip would like to provide a comprehensive view of emerging machining technologies to its guests by inviting partners to present their technologies through product showcase and technical seminars.

“We have incorporated our partners solutions in our machining and automation demos to showcase their respective applications to provide an insight to customers on how these solutions can improve their productivity. Most importantly, we appreciate that our customers have set aside their precious time to attend our open house, and we hope to reciprocate by sharing solutions and knowledge that could help improve their profitability,” he stated.

Technology Collaboration

Hurco also invited its technology partners: Automatic Controls and Instrumentation Pte Ltd, Blaser Swisslube (Singapore) Pte Ltd, EMUGE-FRANKEN Singapore Pte Ltd, MMC Hardmetal (Thailand) Co. Ltd (Singapore Branch), OMRON Electronics Pte Ltd, SCHUNK Intec Pte Ltd, and Karl Schussler GmbH & Co. KG during the open house for a seamless experience for all visitors, with completely optimised technology solutions running on a full spectrum of machine tools. Learn from Omron Electronics about his collaboration with Hurco.

Koh Beng San, Manager, Systems Solution Sales, Omron Electronics Ptd Ltd have been working with Hurco for more than five years. He confirmed, “We understand customer requirements. In fact, we started our first product integration even before the pandemic started. Our intention is to help customers and become their partner in improving their production and achieving automation.”

Hurco is a well-known CNC machining brand in Singapore, and CNC machine turning is doing quite well not only here in Singapore but also in the entire Asia Pacific region. During Covid, one of the issues faced by customers is manpower, and because of that they cannot do much production. He said, “Our goal is to help adjust the manpower shortage and start using robots in machine tool turning and other machine tool methods.”

Koh added, “Here in Singapore, I see two types of customers: one who is willing to automate their manufacturing process and those who are reluctant to try and integrate automation in their production. This collaboration with Hurco, which is a convergence of technology-- CNC machine turning and robotics, will allow customers to embrace opportunities in automation.”

Customer Experience

K1 Precision Pte Ltd

Louis Loh, Director, K1 Precision Pte Ltd, announced, “We provide precision machining to local customers in the semiconductor, medical and aerospace industries, and a customer of Hurco for more than 10 years. Currently we are using 23 machines from Hurco,  and planning to purchase a Hurco turning machine. Working exclusively with one single company like Hurco can bring special advantages. For example, because the machines are all the same brand, we do not need to worry about dealing with a wide range of products, the risk of errors, shortages and other problems is reduced, plus we are so near that we can call them anytime for service. When you are familiar with the strength of the machine tool, you find that you have much better results. As for the open house, automation is something new for my technicians."

Automation features many different types of task solutions and equipment varies. Each of these performs different tasks and has different capabilities. He revealed, “Hurco is very helpful in teaching us to understand some of the differences between them in order to choose a system that is right for our automation challenge. It is not just about deciding to automate but having the right partner, like Hurco, with us is just as important.”

TMO Manufacturing Pte Ltd

TMO Manufacturing Pte Ltd specialises in precision CNC machined parts out of a wide range of materials.

Lim Ming Jing, Ivan, Production Manager, expressed, “Hurco has been our partner for over 10 years. We chose to partner with them because they have reliable 3- & 4-axis milling machines in terms of price points, plus they are very responsive when comes to after-sales services. During the pandemic, they were able to provide us with the needed machines to expand our production capacity despite the pandemic. Responsiveness and timeliness are so crucial to our success, and we are very happy that Hurco is our partner here."

Now that more companies are turning to robotics and automation, Ivan Lim said this open house is definitely an eye opener for them. “We understand that the need for automation continues to grow as labour shortages affect companies’ ability to serve their customers. Yes, we are using Hurco machines but it is the integration of robotic automation with Hurco machining centers that we are most interested for the future of our company. In this open house, we see an automation system that is portable, easy to set up, easy to program and affordable.”

Rei Promax Technologies Pte Ltd

Toh Wei De, Development Mechanical Engineer, Rei Promax Technologies Pte Ltd, said, “We customised precision components for the semiconductor industry and lately we are entering the aerospace industry. We supply to local Singapore customers and some US owned companies. We have partnered with Hurco because we find that their machines cater to our needs.”

Right now, Rei Promax is using 3-axis and 3 plus 2-axis CNC machines. “We have very good experience using Hurco machines because of the increase in our productivity. During the pandemic, our operations have been disrupted due to lack of manpower. Most of our employees need to go back to their home country. I think the idea of robots integrated in our machines is important for the growth of our company in the future. Right now, we are running high-mix manufacturing, producing 20 units overnight. So, I think the ProCobots is suitable for our business,” Toh Wei De confirmed.

He added, “The semiconductor industry is slowing down but we expect it to pick up second half of 2024. Let us see in the future as we get more projects. Of course, we also need to compute if the ROI is good for use, then we may invest in a machine with Omron robot inside. I can say that the open house is really very good. The seminar is more comprehensive and I find that my technicians understand and see the benefits well.”

Attendance on this year’s Hurco open house in Singapore was encouraging, despite the headwinds in the economy. The manufacturing industry has had a buoyant 2022, it’s an immense challenge, but something we can surely overcome. If automation can send humans to a space station just imagine what it can do in industrial manufacturing industry.

Scan for open house video:

Exclusive interview with new RMI Pressure Systems director

By: Kathryn Gerardino-Elagio

The use of emerging technologies such as the Industrial Internet of Things (IIoT), artificial intelligence, and Big Data is becoming more common in the pump industry. Because of the volatile nature of the pump industry in recent years, makers of reciprocating pumps and other pumps have focused on providing smart pumping systems in order to maximise earnings. Reciprocating pump manufacturers are relocating their manufacturing plants to China, where labour costs are cheaper, in order to capitalise on the cost-effective advantages of reciprocating pumps and increase profitable sales in such high-potential Asian countries.

 

Early May this year, high pressure reciprocating pump specialist RMI Pressure Systems has promoted Sabrina Zhang to the role of Director for Aftermarket Sales, Services and RMI Operations in China.

International Metalworking News for Asia (IMNA) interviewed Sabrina to talk about the global trends, customer expectations, requirements, and opportunities.

 

IMNA: What are the global trends in the high-pressure pumps industry?

Sabrina: Users of high-pressure pumps are increasingly focused on energy efficiency and sustainability. We have seen this trend clearly in China. Just a decade ago, for instance, our patented ODIN® (On Demand Intelligence) control logic system was a significant innovation in the local market – using variable speed control to optimise performance and save energy. Today, it is common to see longwall mining tenders specifying the inclusion of variable speed drives in a system. Customers really pay attention to efficiency, as this can deliver considerable financial savings.

We have also seen rapid developments in the technology and design of high-pressure pumps, including the material used. This has led to more robust products and user-friendly control systems.

Predictive maintenance has also been an important focus in China, combined with remote monitoring of high-pressure pumps systems. This has a special relevance for underground mining, as it allows personnel to perform more of their work from surface – enhancing both safety and productivity as personnel do not need to travel to the coalface as often, and can spend less time in potentially hazardous zones. In addition to monitoring, the operator can even control aspects of the pumps remotely.

IMNA: Have you noticed any changes in the expectations and requirements of your customers in China (APAC) since the Covid-19 pandemic?

Sabrina: Most readers will be familiar with the very strict lockdowns in China over the three years of the Covid-19 pandemic; during this time, coal mines still needed to meet certain production targets so that the country had electrical power. Our customers therefore needed reliable and uninterrupted access to spare parts and service. The severe disruptions to the global supply chain meant that we had to keep more inventory – both at our factory in Shanghai and at our warehouses close to our customers.

We also ramped up our localisation strategy to deal with the logistical uncertainties of importing goods; this led to more local sourcing, so that we could shorten our lead times to customers. With the travel restrictions, we also located service engineers closer to the mine sites so that they could visit customers regularly and maintain a high level of technical service.

One of the main outcomes of the Covid-19 pandemic was that equipment manufacturers and suppliers had to find innovative ways to improve the resilience of their supply chains. Among the ways we achieved this as RMI Pressure Systems was by upgrading our Shanghai production facilities and diversifying our sourcing strategy.

IMNA: How do you view the adoption of high-pressure systems in the Asia Pacific region?

Sabrina: High pressure reciprocating pumps are employed in many industry sectors from mining and steelmaking to oil and gas – with various applications requiring their own performance specifications or even materials of construction. There is a competitive market in the supply of these high-pressure systems, although there is a wide variety in the quality of offerings and their reliability. As an early entrant to the market in China, RMI Pressure Systems have been differentiated through our robust design and our manufacturing expertise. These factors give customers high uptime levels and longer equipment life – for a lower total cost of ownership.

IMNA: What is your role in driving growth for your products and solutions in China?

Sabrina: There are three main areas of focus in my role within RMI China, starting with aftermarket sales – which I have already managed for the past five years. This is a critical area of our responsibility to existing customers, keeping their RMI pumps well maintained and productive. In this way, we have built a loyal customer base that trusts our systems and support.

The second key aspect of driving RMI’s growth in China has been the process of earning certification from the MA Centre, which we achieved in April this year. The MA Centre is the Chinese agency responsible for approving and certifying the safety of mining products before they can be used underground. This opens up the market substantially for us, as we now qualify to participate in many more tenders where our products match the technical tender requirements. Up to this year, we have only been permitted to submit proposals for about three tenders each year; this number now increases potentially to hundreds of opportunities. Of course, our success will rely on our ability to be cost-competitive among many local suppliers. Our localisation strategy is aimed at doing this, while maintaining the high quality for which our pump solutions are known.

Thirdly, we are continuing to develop our marketing channels in China for new system sales, adding to the partnerships we have with local agents, representatives, and distributors.

IMNA: Which business segments make you feel confident about the opportunities ahead for the company in the next year; and are you noticing demand emerging from any new industry or segment?

Sabrina: With our recent MA certification, there are exciting opportunities to grow our presence in the longwall coal mining segment of the market – where we have been established for over 30 years. We expect to increase our new system sales, as we are now able to participate in many more tenders in this segment – and can build on our strong reputation in this industry.

In addition to powering longwall equipment underground, our high-pressure reciprocating pump systems also play a role in dust suppression and cleaning in coal mines. These applications point to a range of other industries that could be potential markets for these systems, such as water and wastewater treatment.

IMNA: What do you think are the key manufacturing priorities in APAC for 2023 and how can your technology give the industry a positive outlook for the future.

Sabrina: Our key manufacturing priorities now are to continue building resilience in our supply chain, while at the same time progress our localisation strategy. These two imperatives are allowing us to diversify our sourcing, to improve pricing and lead times – which in turn will assist us in our efforts to improve cost-competitiveness.

Another important element of our manufacturing strategy is to incorporate more intelligent technology in our system solutions to customers. Beyond our expertise in pump design and manufacture, we are also responding to customers’ needs for automation and intelligent mining strategies. This means gathering and analysing data on pumps’ operating functions, to predict what maintenance is required – thereby avoiding unscheduled downtime. Operators can run our pumps from a centralised operating room, improving safety and efficiency.

Our intelligent emulsion mixer unit, for instance, can measure the concentration of the oil-water mix and keep the concentration within the required parameters. We also use our patented control logic system ODIN® (On Demand Intelligence) to proactively collect the combined face pressure signal and powered roof support initiation of the longwall mining systems – to enhance their performance. This kind of technology is an essential part of building economies that are safe, productive, and sustainable.

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E-mobility with TRUMPF laser technology

By: Kathryn Gerardino-Elagio

Global mobility transition is in full swing. In South East Asia, electric vehicle (EV) and battery industry appears poised for growth. The EV market is expected to reach US$2,665.3 million by 2027, registering a CAGR of 32.73%, according to Mordor Intelligence. More companies, mostly automotive suppliers, are looking for new manufacturing solutions, and laser is at the centre of it.

 

International Metalworking News for Asia (IMNA) caught up with Markus Lindemann, Regional Director, Laser Division of TRUMPF Pte Ltd, during the recent ITAP in Singapore to discuss TRUMPF’s E-mobility solutions made with laser welding.

 

IMNA: Please give us an overview of the best features of TRUMPF’s laser welding for E-mobility?

 

Markus: E-mobility is one of our growth drivers. The change from the combustion engine to the EV cars is a big push for laser applications. For TRUMPF, we are moving our focus to different topics. We start e-mobility in the battery cell manufacturing, where we have developed new processes with scanners to weld aluminium housing. But also slitting and contour cutting as well as welding the battery foils are common application for TRUMPF’s lasers.

 

There are lots of laser applications in the prismatic cells. Main battery cell manufacturing companies in Korea and China are using TRUMPF’s lasers. At the end, the automotive or OEM suppliers take the battery cells and combine it to battery modules and battery packs. The module tray, as well as the other parts like combining the battery cells with the bus bar, is also laser welded. Another important process is laser cleaning which is to remove the coating between the battery cells in the model.

 

In our latest development we also came up with a special process to weld the aluminium cans of prismatic battery cells. With a scanner, you can now do tack welding and final contour welding in one station.

Copper materials are also often used in E-mobility. We have developed a new green laser with pulse function for copper welding to address this market trend. For thinner aluminium sheets and connectors, we use the green laser with a excellent beam quality and laser powering up to 3kW. But for thicker copper material (e.g.  thickness of more than 1mm) we still use infrared laser with a scanner optic. We compare different technologies in-house and look for the best solution. It is not only about the optics and the laser source, but also about vision systems, quality control, and welded measuring-- that is another focus of TRUMPF. We are moving towards a holistic approach in offering as a laser system provider including vision and sensor systems. And with these optimised optics and vision system, combined with application know-how, we develop a technological advantage for our customers.

 

IMNA: Considering the present weak market, could you say laser welding is positioned to be a cost-efficient solution?

 

Markus: Lasers will be only used if you can reduce your production cost by using a laser source. Typically, laser is either used in high volume production where we have a fully automated process, and everything is clearly defined and accurate. On the other hand, laser gives you an advantage in being able to produce different parts without any customised tool for it. Cause at the end, it is always the laser light and you have to apply this in a certain way through programming and that makes a laser very flexible to work. In both cases, the laser will only be used if it can reduce the cost.

Another aspect is quality. Laser can achieve new qualities, such as different product features. For instance, you can make the part smaller and more precise compared with other technologies. This is of course one of the strengths of laser technology -- you can explore new applications and product design by applying laser technology.

 

IMNA: Do you see encouraging signs in Asia’s manufacturing capacity utilisation?

 

Markus: Our focus in South East Asia is of course finding customers who have local R&D, but I realised that a lot of R&D is not done here. It is mainly a production hub where processes are developed in Europe and in America, and have transferred their production here. In this case, you do not have much influence on the decision-making process. Once you develop the process, the production side will just follow according to the test before, so there is a limit in developing new things here.

 

But we do have some partners in SEA who develop new things for a local market. For example, we have a customer in Thailand making automotive parts. They came to us saying, “We have this bended tube parts and we need a 3D cutter to cut holes and ends.” We did the testing and came up with a solution. We discussed the costing, investments, and cycle times. In the end, it materialised. It has turned out into a project that is going for more than 4 years but finally we are happy to see TRUMPF’s TruLaser Cell machines fully-automated. That is the first fully automated production line I have seen in SEA for parts like this. This gives me confidence that there is still a need for such solutions in South East Asia and not only in other part of the world You just need the right partners for this journey.

 

IMNA: What do you think are the key manufacturing priorities for 2023 and how can TRUMPF technology give the industry a positive outlook for the future?

 

Markus: Digital solution is the upcoming trend. We move away from the basic machines and if there is an issue, we send a service engineer for repair. I think this is in some ways still state-of- the-art. But this will fade out soon and at TRUMPF we are going into digital manufacturing. On the machine toolside, we have the smart factory where we organise the whole production system. We help the customer to reduce their material storage cost, to optimise the piece flow, optimise the usage of our machines, and gain more by using smart technology.

 

On the laser side, we are using condition monitoring that connect our lasers at the customers through cloud with our headquarters in Germany. They receive the data and apply AI to it. If they see something critical, they will feedback to our local service team, and they will contact the customer to schedule a visit in the next few days. The service team will inform the customer that their machine might be down in the next 30 days and ensure that the required spare parts will be available upon the scheduled visit. This allows the customer to plan their down-times. We also have the first installation in Indonesia already and we have ongoing discussions with customers in in the Philippines and Thailand.

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Renishaw brings advanced manufacturing solutions to South East Asia

 By: Kathryn Gerardino-Elagio

Steve Bell, General Manager of Renishaw ASEA

Manufacturers nowadays are progressively looking to automation in order to propel operational efficiency and overcome skill shortages on the shop floor. To control manufacturing processes on the shop floor, the need for new process control methods, such as gauging systems are increasing.

 

In a conversation with Steve Bell, General Manager of Renishaw ASEAN, at the recent Industrial Transformation Asia Pacific 2022 (ITAP 2022) in Singapore, he highlighted the Equator 300 and 500 flexible gauge system, which is suitable for automation requirements.

 

According to Steve, the Equator 300 versatile gauge is a smaller standalone Equator, while the Equator 500 is the larger system that enables the gauging of larger parts, with a working volume of 500mm in diameter and up to 400mm in height. Both are designed to provide speed, repeatability, and ease of use for manual or automated applications.

 

“We are showing the Equator here at the show to demonstrate how it can help customers in an automation environment. Our focus is very much on products that land themselves to automation, such as our Equator, automated gauging system, machine tool probing, calibration those are the areas we are focused on” he explained.

 

Equator gauging system

The Equator is a highly valuable option for manufacturers who are looking to replace their current gauging method.  Its system enables process control by delivering highly repeatable, thermally insensitive, versatile, and re-programmable gauging to the shop floor.

 

Purchasing an Equator will see a rapid return on investment – Equator’s automated system can greatly increase throughput and naturally will simultaneously reduce labour costs.  The Equator is also a fraction of the cost of an equivalent custom gauging system, including associated fixturing.  There is also no need to pay for expensive rework of custom gauges in order to gauge modified or new parts because of the Equator’s re-programmable readiness.

 

Most users of Equator systems need short cycle times to maximise throughput from their manufacturing processes. Both Equator 300 and 500 systems, while maintaining high levels of repeatability, are capable of rapid scans and high-speed touch points on a wide variety of features. Years of customer experience with Equator systems have proven the capability to gauge size, position, and geometry on a single device. This can eliminate the need to stabilise parts to the temperature of the quality room prior to measuring geometry and form of critical features.

 

Improved efficiency solution

Steve said that its message is all about “Improved Efficiency Solution.” “I think more than future trends, we see a continuation of where things are going right now. I think we are going to see quite a difficult time for the world economy and we must be as efficient as we can be. Both in terms of our own operation and the products that we sell to our customers. The future is going to be electric vehicles (EVs), wherein everything will be connected with EV-- the battery production, energy production in general. All those are pretty much our focus,” he stated.

 

Market growth in South East Asia

As restrictions ease and borders open in South East Asia, more opportunities arise for market expansion. With countries now on the road to recovery after massive losses from the COVID-19 pandemic, the region is once again becoming one of the world’s most attractive emerging markets.

 

For Renishaw, the company is maximising the market opportunities in South East Asia. There is a wealth of opportunities for its business in the region. Steve shared, “Singapore’s semiconductor industry has received a lot of growth. We also see oil and gas coming back strong, including aerospace. Thailand still has a lot of business with automotive, while consumer electronics are growing in Vietnam and the Philippines.”

 

Newly renovated Bangkok facility

With the promising outlooks for Renishaw in South East Asia, the company is refurbishing its Bangkok facility. “Right now, we are doing a major overhaul of our Bangkok facility. Steve revealed, “We are building a state-of-the-art showroom on the ground floor. This is a major refurbishment. Thailand still has a lot of business with automotive, but increasingly more on EV projects coming into Thailand.”

 

He added, “The refurbished facility makes it more feasible, logistically, for Renishaw to work cooperatively with customers and potential customers in Thailand, and develop solutions specific to them.”

 

The renovated Bangkok facility is designed to provide venues where automation adoption process can be accelerated. Steve, further said, “We can give companies cost-effective, hands-on experience of our products, combined with application engineering support to optimise their design, and post-processing capabilities to ensure that it performs as it should.”

Important Strategy

The increased production of new energy vehicles, including hybrids and full EVs, has seen a major shift in automotive engineering and manufacturing practices. Production flexibility and adaptability as technologies are continually refined are fundamental to commercial success on the journey to EV.

Steve disclosed, “One of our important strategies is to recognise that the internal combustion engine (ICE) will not be around that much longer. A lot of our customers especially for inspection and metal cutting products are heavily involved with that industry. So, we must shift our focus to the future which is EV. We are very much involved in developing products and systems to address the needs of the EV industry. There are a lot of things happening in the EV industry, consequently we will also be developing a lot of products to address these needs.”

 

As new automotive technologies continue to be refined, production flexibility and adaptability will be fundamental to commercial success on the road from conventional ICE to full battery EV. Renishaw's manufacturing solutions provide the speed, flexibility, and ease of use to help you adapt your production for this electric future.