Big Kaiser has won the Global Industry Award 2020 in the category ‘production performance’ for its EWA, a fully automatic fine boring tool.
The EWA was submitted for the award through Boulland DPM, Big Kaiser’s partner in France. The production performance category highlights innovations focusing on the significant improvement of key metrics or performance through productivity gains.
Giampaolo Roccatello, Head of Sales and Marketing at Big Kaiser, said: “For more than 30 years, Boulland DPM has been an expert representative and supplier of Big Kaiser tool systems in France. We congratulate and thank Boulland DPM, and are delighted that the EWA, and its pioneering role towards Industry 4.0, has been recognised with this prestigious award.”
The EWA is an intelligent fully automatic fine boring tool, which does not require a human operator. It achieves fast, accurate boring because the process does not need to be stopped to make measurements and to manually adjust the fine boring tool. As well as saving time, this minimizes costly scrap resulting from manual adjustment errors.
The new EWA features a powerful motor for robustness and reliability. It is sealed against dirt and water in accordance with IP69. The clamping system provides additional stability and repeatability to deliver consistently high reliability and precision at cutting speeds above 200 m/min.
Jose Fenollosa, Head of Research & Development at BIG KAISER, said, “The EWA is far ahead of the rest in its level of automation and sophistication – which gives our customers real benefits in terms of time and money saved, and makes it ideal for Industry 4.0 applications. We are talking to potential customers now, including some of the leading machine manufacturers. The final EWA product will be available in 2020.”
The EWA can be used in three primary configurations.
The EWA features wireless connectivity to BIG KAISER’s user-friendly smartphone and tablet app for easier tool monitoring and configuration. It can also automatically communicate with a pre-setter, so diameter measurements can be transferred without operator intervention.
For legacy machine tools, a PC interface between the machine tool and the EWA can be used to provide a fully-automated, closed-loop control cycle, where commands are sent from the machine tool to the EWA, automatically adjusting or stopping the machining process when required.
Fully integrated system
For newly-developed machine tools, EWA control software can run directly on the machine tool itself to provide an equivalent level of automatic control, requiring no external control device.
At EMO 2019 the EWA has been shown working in operation on a FANUC CNC machine, with the entire boring cycle performed automatically: making the initial bore, measuring it and then adjusting the tool to complete the final bore.
The new EWA will initially come in two versions: the EWA peripheric, covering diameters from 68 mm to 90 mm and the EWA centric from 10 to 54 mm. Other models for different adjustment ranges are currently in the design phase.
The EWA can be used with BIG KAISER’s extensive standard range of accessories, making it easy to add to an existing system. To maximize flexibility, the EWA 68 model offers an adjustment range of 22 mm, which is substantially larger than similar solutions available in the market today. The EWA has an integrated accelerometer that measures vibrations during the cutting process and in the event of excessive vibrations, alerts the machine tool to automatically adjust its cutting parameters accordingly.
The EWA 68 with tablet control is expected to be available for sale in mid 2020. Further models and configurations will follow.