Advancing sustainability in machine tool operations: A path to greater efficiency and reduced carbon footprint

The transition to greener manufacturing practices not only addresses ecological concerns but also offers financial benefits by lowering the total cost of ownership (TCO). At the heart of this movement, HEIDENHAIN has been developing innovative solutions designed to enhance productivity, quality, and process reliability in machine tools, all while reducing their carbon footprint.

Enhancing Productivity through Context-Sensitive Guidance: The New HEIDENHAIN TNC7

One of the key advancements in CNC control technology is HEIDENHAIN's TNC7, which now comes in new hardware versions to accommodate a wider range of applications. With monitor sizes available in 24-inch, 19-inch, and 16-inch options and two different keyboard designs, the TNC7 offers flexibility for various machine configurations. Notably, the 16-inch monitor version, known as the TNC7 Basic, is tailored for 3+2-axis machines and serves as a replacement for the TNC 620. This model retains the high-performance features of its counterparts, including a Full HD monitor and access to a comprehensive suite of software options, such as MAS graphical 6D setup support, DCM collision monitoring, and OCM trochoidal milling. These capabilities improve user-friendliness, boost efficiency, and provide greater process reliability, aligning with the goals of sustainable manufacturing by reducing errors and waste.

Digital Solutions for Real-Time Energy Monitoring: StateMonitor’s New Capabilities

A major step toward sustainability is optimising energy consumption on the shop floor. HEIDENHAIN’s StateMonitor software has been upgraded to include energy monitoring capabilities, providing machine operators with real-time insights into the power usage, compressed air consumption, and process water utilisation of their CNC machines. This data allows for precise adjustments that reduce energy waste, directly impacting operational efficiency. Moreover, the software now offers ERP interfacing, enabling seamless integration with higher-level ERP and MES systems for more comprehensive data sharing. This feature ensures that production data is readily available, further enhancing the digital ecosystem and driving sustainable manufacturing practices.

All-in-One Tool Inspection with the VT 122 Measuring Camera

Tool inspection is another area where efficiency and sustainability converge. HEIDENHAIN’s VT 122 measuring camera, equipped with VTC software, is designed to streamline tool inspection processes by combining three functions into one system. Acting as a tool presetter, microscope, and visual inspector, the VT 122 enables operators to examine tool edges directly within the machine envelope, eliminating the need for external metrology labs. This holistic tool analysis capability not only increases productivity but also extends tool life, thereby reducing overall costs and environmental impact. The system’s ability to automate tool measurements, document wear, and provide reproducible results supports sustainable practices by minimising downtime and material waste.

Reducing Scrap and Increasing Cutting Time: The TD 110 Tool Breakage Detector

Tool breakage is a common cause of machine downtime and scrap generation, both of which can undermine sustainability goals. The HEIDENHAIN TD 110 tool breakage detector addresses this issue by performing rapid on-machine tool inspections, saving valuable time and reducing material waste. By identifying broken tools as they are transferred between the machine tool’s magazine and envelope, the TD 110 accelerates the inspection process by up to six seconds per tool change. This real-time detection capability not only improves process reliability but also minimises the environmental impact associated with scrapped parts, making it a valuable addition to any sustainable manufacturing initiative.

Cutting Carbon Emissions with HEIDENHAIN Encoders: True Image Technology

HEIDENHAIN’s encoders, featuring True Image technology, represent a breakthrough in reducing the carbon footprint of machining operations. Contamination from coolants and other liquids is a common challenge in machine tools, often requiring purge air systems to ensure accurate readings from encoders. However, HEIDENHAIN’s LC and LB linear encoders, along with the RCN and ECA angle encoders, deliver precise scale readings even in contaminated environments. With True Image technology, these encoders eliminate the need for purge air in many applications, reducing energy consumption by up to 99%. This reduction not only simplifies system design but also dramatically lowers operational costs and environmental impact, positioning HEIDENHAIN’s encoders as a key component in sustainable machine-tool operations.

Conclusion: The Future of Sustainable Machine Tool Operations

As manufacturers seek to reduce their environmental impact, technologies that enhance productivity, optimise energy use, and minimise waste are crucial. HEIDENHAIN’s suite of advanced solutions, including the TNC7 control, StateMonitor software, VT 122 measuring camera, TD 110 tool breakage detector, and encoders with True Image technology, are leading the way toward more sustainable and efficient machine tool operations. By adopting these innovations, manufacturers can take significant steps in reducing their carbon footprint while simultaneously improving their bottom line.

Source: HEIDENHAIN