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Reichmann & Sohn
MAUS CAAT software optimizes machining programs for MAUS automated grinding machines.

Self-Optimizing Grinding Program

June 30, 2023
Patent-pending software with “computer aided automatic tuning” functionality will optimize machining programs to improve cycle times and productivity.

REICHMANN & SOHN’s patent-pending MAUS CAAT software optimizes machining programs for MAUS automated grinding machines in dimensions that had not been previously possible. Initial tests confirm the software's promising potential with cycle time and productivity increases in automatic grinding in the double-digit percentage range.

The software was shown publicly for the first time at GIFA 2023.

Machining programs can be created on a Windows-based interface through intuitive teach-in with structured plaintext comments. This reduces the time required for programming and ensures a high degree of clarity, a quick-learning curve, and a high level of acceptance, especially for machine operators without prior knowledge.

The optionally available laser measurement compensates for tolerances in the tenth of a millimeter range and thus ensures finished contours.

An automated machine that is easy and safe to operate will help foundries attract personnel for casting finishing tasks, which in turn will help to ensure that capacity is maintained and productivity can be increased.

The new operating system for the MAUS grinding machines offers potential for Industry 4.0- and 5.0- compatible operations, and can support the user with the help of state-of-the-art technologies such as IIoT or artificial intelligence, to increase machine performance and productivity. With the new, "computer aided automatic tuning" self-optimization software for MAUS grinding machines (“MAUS CAAT” for short), Reichmann is taking a first step to making use of these possibilities. For the first time, machine data such as the spindle and drive power during operation are available to the operator in a structured form and can be used for optimizations manually and automatically.

Program codes created by machine operator for finishing castings are analyzed block by block with the help of MAUS CAAT. During the machining process of the first castings, the software specifically detects even the smallest defects and optimization potentials in the program. Wherever there is potential for increasing spindle and drive performance, the feed rate is increased iteratively. In this way, MAUS CAAT optimizes the machining program in the shortest possible time to achieve top performance with maximum time savings while making optimum use of the machine's output. In addition, the software adapts the machining speed to the weight of the casting directly during machine loading. This means that relatively light workpieces can be machined even faster. This results in a perfect interplay of human and machine intelligence.

"In initial tests, MAUS CAAT was able to speed up ready-optimized teach programs by over 15% and provide the appropriate input to the programmer for further optimizations. That's 15% more parts in the same time," reported Rafael Dineiger, international sales manager at Reichmann & Sohn GmbH. These accelerations would classically only be possible to a significantly limited extent using the multi-eye principle and with considerable time expenditure. "

The easy-to-understand user interface of the MAUS machines helps the machine operator to set-up and use the software easily and parameter-controlled as required. Foundries that presently operate MAUS grinding machines can save time and costs by automatically optimizing the program sequences and maximizing their productivity.

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