BIG KAISER EWA Automatic Fine Boring

The EWA is an intelligent, fully automatic fine boring tool, which performs closed-loop boring operations. With the EWA there is no need to stop the machine tool to take measurements and manually adjust the boring tool, resulting in considerable time savings.

EWA AUTOMATIC FINE BORING SYSTEM

AUTOMATIC FINE BORING

THE FUTURE OF FINE BORING The EWA is an intelligent, fully automatic fine boring tool, which performs closed-loop boring operations. With the EWA there is no need to stop the machine tool to take measurements and manually adjust the boring tool, resulting in considerable time savings. By eliminating human interaction, the likelihood of scrapping expensive workpieces is minimized. This reduces costs and improves accuracy, enables handling of multiple bore sizes and repeatable bores, and avoids time-consuming manual wear-out compensation. Developed solely by BIG KAISER, the EWA system is based on BIG KAISER‘s EWE digital fine boring heads and the EWN precision boring heads.

The EWA can be Integrated in Three Primary Configurations:

Tablet Control It can be operated as a standalone tool, controlled manually with a tablet via wireless connection.

PC Control 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 the tool in synchronization with the machining process. Fully Integrated System The full system can only be integrated on new machine tools. The EWA control software runs directly on the machine tool itself, requir- ing no external control device.

INNOVATIVE The internal development of all systems allows for additional features in the future

EASIER The EWA fine boring head adjusts automatically

SERVICE BIG KAISER offers exchange service for all EWA products. In the event of failure, production never stops

FASTER No machine down time; all boring processes are done in real time

SAFER Due to in-process measuring, bores are always the correct size

AUTOMATIC FINE BORING

SPECIFICATIONS

Built-in accelerometer

Battery powered

Internal motor for automatic tool carrier adjustments

Bluetooth ® communication to external devices

Internal actuator for clamping tool carrier

Wireless Communication

Bluetooth ® Low Energy

Work Range EWA68

Ø2.677"-5.276" (Ø68-134mm) with overlaps (3 insert holders)

Adjusting Range EWA68

.433" (11mm) of radial travel

Adjusting Precision

±.0001" (±2 μm)

Maximum Cutting Speed

984 SFM (300 m/min) Max 580 psi (40 bar)

Recommended Coolant Pressure

Battery

CR123

Battery Life

Approx. 10 ft (3 m) total movement of cartridge

Adjusting Speed

Approx. .031" (.8 mm/s)

Communication Range Cutting Stock Allowance

30 ft (10 m)

Max Ø.012" (Ø.3mm)

Wake-Up Function

Accelerometer (tool ON with movement or rotation)

Flashing Green: Tool is ON Flashing Blue: Tool is connected Flashing Yellow: Tool is being adjusted Flashing Orange: Warning Flashing Red: Error OFF: Tool is OFF

LED Indicator

AUTOMATIC FINE BORING

EWA FINE BORING TOOL KIT BORING RANGE: Ø2.677"-5.276" (Ø68-134mm)

The ultimate expression of automatic boring with flexibility, precision and safety all rolled into one. In conjunction with any measuring probe, it makes the boring process automatic and always in tolerance. The wide range of diameters is covered with just three insert holders.

Catalog Number

Reference Number 10.310.985 10.310.986

Description

EWA68-134CKB6SET-M1 EWA68-134CKB6SET-M2

Tablet Control

PC Control

10.310.985 — Tablet Control Tool Kit Contents

10.310.986 — PC Control Tool Kit Contents

Catalog Number

Reference Number

Catalog Number

Reference Number

Qty.

Boring Head

EWA68-134CKB6

10.310.980

EWA68-134CKB6

10.310.980

Electronic Accessories EWA Controller

Mechanical Accessories / Insert Holder ENH8-1T

10.719.020 10.719.021

1 1

10.626.164 10.626.165 10.626.166

1 1 1

EWA Antenna

ENH8-2T ENH8-3T

Mechanical Accessories / Insert Holder ENH8-1T

10.626.164 10.626.165 10.626.166

1 1 1

Mechanical Accessories / Insert TCGT-110204-M20C

ENH8-2T ENH8-3T

10.655.318

Case

Mechanical Accessories / Insert TCGT-110204-M20C

Case-EWA68-134CKB6SET Case-EWA68-134CKB6

10.671.180 10.671.181

1 1

10.655.318

Case

• Tool Kit does not contain a smart phone or tablet; BIG KAISER recommends using an Android device

Case-EWA68-134CKB6SET Case-EWA68-134CKB6

10.671.180 10.671.181

1 1

AUTOMATIC FINE BORING

EWA FINE BORING HEAD BORING RANGE: Ø2.677"-5.276" (Ø68-134mm) The EWA single cutter boring tool for automatic boring covers a range of Ø2.677"-5.276" (Ø68-134mm).

L 2

L 1

Catalog Number

Reference Number

Adjusting Range

Front Bore ØD

Back Bore ØD

Weight (lbs.)

ØD 1

L 1

L 2

EWA68-134CKB6

10.310.980

.433

2.677-5.276

3.110-5.276

2.520

3.425

3.276

1.496

4.0

INSERT HOLDERS TYPE E Standard holder with 87º entering angle, suitable for fine boring in through and blind holes. Three different insert holders for the extension of the diameter range and for back boring applications.

Size 3

Size 2

L 1

Size 2

Size 3

Size 1

Catalog Number ENH8-1T ENH8-2T ENH8-3T

Reference Number 10.626.164 10.626.165 10.626.166

Insert Holder Size

Front Bore ØD 2.677-3.543 3.543-4.409 4.409-5.276

Back Bore ØD 1 3.110-3.543 3.543-4.409 4.409-5.276

L 1

1 2 3

.492 .925

3.425 3.425 3.425

1.496 1.496 1.496

TC 11

1.358

AUTOMATIC FINE BORING

TABLET CONTROL Standalone tool, controlled manually with a tablet via wireless connection.

Semi-Automatic Process This solution represents the lowest level of integration. The fine boring head needs to be connected with an App running on a tablet or smartphone. The EWA can be used on machines with BT/BBT30-40-50, CV/BCV(SK)40-50, BIG CAPTO 5-6-8 and HSK-A63-80-100-125. The boring head will be automatically adjusted according to the information the operator inputs into the BIG KAISER App. Manual Measuring Once a bore is produced with the EWA, the operator can stop the boring cycle and measure the actual bore size with a precision bore gage or an in-process tactile probe, and input the correction into the tablet. The EWA will self-adjust to the correct value. It is recommended to repeat the measurement after the final boring cut to approve the correct target diameter. Machine with Measuring Probe The measuring probe is used for the bore measurement and integrated in the machine control. It is necessary to program the machining cycle to prevent dimensional failures. The machining program will stop the boring cycle in the event of an out-of-tolerance bore and display an error message alerting the machine tool operator to make the required adjustment with the tablet.

EXAMPLE FOR MANUAL APPLICATION Requirements

Bore Target Ø: 2.756" Tool Pre-Set Ø: 2.752" Initial Rough Bore Ø: 2.748"

Manual Process

Automatic Process

Cut and Measure Measuring Bore 2.752"

Calculate Adjustment (.004")

Measure Bore (2.756")

Measure Rough Bore 2.748"

Tool Pre-Set 2.752"

Adjust Tool (.004")

Produce Final Bore

END

BORE < TOLERANCE

BORE WITHIN TOLERANCE

Decision

BORE > TOLERANCE

ALARM

AUTOMATIC FINE BORING

PC CONTROL Closed-loop system with the integration of an EWA controller.

Automatic Process Via EWA Controller Integration In this solution, the integration with a legacy machine tool is done via a specific application running on an EWA controller. The EWA can be used on machines with BT/BBT30-40-50, CV/BCV(SK)40-50, BIG CAPTO 5-6-8 and HSK-A63-80-100-125. This integration needs to be setup on site since much depends on the machine tool control type. Different machine tool control models may require additional integration efforts. The machine tool must be equipped with high-precision measuring probes for bore size measurement. The PC acts as a synchronization interface between the machine tool and the EWA. It stops the machining cycle after the touch probe makes a measurement, reading the result and sending the corresponding adjustment value to the EWA. After the EWA has been adjusted, the PC notifies the machine tool to continue the process. The machine code needs to be written according to the following flow chart.

EXAMPLE FOR AUTOMATIC APPLICATION Requirements

Bore Target Ø: 2.756" Tool Pre-Set Ø: 2.752" Initial Rough Bore Ø: 2.748"

Automatic Process

Cut and Measure Measuring Bore 2.752"

Calculate Adjustment (.004")

Measure Bore (2.756")

Measure Rough Bore 2.748"

Adjust Tool (.004")

Tool Pre-Set 2.752"

Produce Final Bore

END

BORE < TOLERANCE

BORE WITHIN TOLERANCE

Decision

BORE > TOLERANCE

ALARM

AUTOMATIC FINE BORING

FULLY INTEGRATED SYSTEM Closed-loop system integrated in the machine tool control.

Automatic Process Fully Integrated in New Machine Tools This solution is fully integrated within the machine tool control; additional PC is not required. The interaction with the operator is done in the machine tool HMI via an App or a technology cycle. The EWA can be used on machines with BT/BBT30-40-50, CV/BCV(SK)40-50, BIG CAPTO 5-6-8 and HSK-A63-80-100-125. The machine tool must be equipped with high-precision measuring probes that communicate with the machine control. It is necessary to program the machining cycle to prevent dimensional failures.

EXAMPLE FOR AUTOMATIC APPLICATION Requirements

Bore Target Ø: 2.756" Tool Pre-Set Ø: 2.752" Initial Rough Bore Ø: 2.748"

Automatic Process

Cut and Measure Measuring Bore 2.752"

Calculate Adjustment (.004")

Measure Bore (2.756")

Measure Rough Bore 2.748"

Tool Pre-Set 2.752"

Adjust Tool (.004")

Produce Final Bore

END

BORE < TOLERANCE

BORE WITHIN TOLERANCE

Decision

BORE > TOLERANCE

ALARM

AUTOMATIC FINE BORING

BUILDING BLOCK The integration of an automated system requires the use of different resources, a combination of hardware and software. BIG KAISER can provide its customers with all or parts of these systems according to their requirements. Please find below an overview of the various systems.

Catalog Number

Provider

10.310.980

EWA Boring Tool

EWA Controller, including:

Controller Hardware

10.719.020

EWA-Sync Software

APIs for Machine Tool Communication*

APIs for EWA Wireless Communication

10.719.021

2.4 GHz Waterproof Antenna

Touch Probe

Machine Tool Program Examples

Installation

z BIG KAISER

z Customer

*Supported Machine Tool Controls: - All Fanuc with Focas2

- Siemens Sinumerik 828D, 840D and ONE - Heidenhain TNC530, TNC620 and TNC640 - Support for other controls is currently in development; contact BIG DAISHOWA engineering to discuss your requirements

SOFTWARE The control software for EWA tools runs on Windows 7 or higher, preferably on an industrial PC. This software provides the communication to the machine tool control via Ethernet and to the EWA fine boring head via Bluetooth ® . The Bluetooth ® connection is established thanks to a magnetic antenna directly connected to the PC, and placed inside the working area of the machine tool. The main function of the control software is to synchronize the machining process with the automatic tool adjustment by sending information from the machine tool to the EWA and vice-versa. Additional functions include: • Semi-automatic control of the EWA by manually introducing adjustment data in the software

• EWA tool configuration • System configuration • Detailed information on error codes (e.g. battery low, tool blocked, etc.)

• Reading log file of the EWA tool • Installation support functions The software is prepared for communication with the most common controls by Fanuc, Heidenhain and Siemens. Communication to other control types is currently in development.

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