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 and minimized scrap.
FULLY AUTOMATIC FINE BORING TOOL The Future of Fine Boring
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FEATURES • Increase productivity • Lights-out operation • Shorter cycle time
• One tool for multiple bore sizes (EWA 68) • Compatible with most machine tools and all probing systems • Straightforward communication protocol • Simple installation
• Adjust in difficult-to-reach locations • Reduces scrap caused by human error
FULLY 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 and minimized scrap. This reduces costs and improves accuracy, enables handling of multiple bore sizes and repeatable bores, and avoids time- consuming manual wear-out compensation. Developed 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 two primary configurations: App Control
It can be operated as a stand-alone tool, controlled manually with the BIG KAISER App via wireless connection. Machine Control Integration For new or legacy machine tools, a PC-based interface between the machine tool and the EWA provides a fully automated, closed-loop control cycle. Commands are sent to the EWA system using macro-variables, automatically adjusting the tool in synchronization with the machining process.
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EWA 68 • Range: Ø68-134mm (with standard insert holders) • Up to Ø861mm with bridge tools • Boring precision of IT3 • Stroke: 22mm/Ø • Absolute linear sensor: precision 2µm
FULLY AUTOMATIC MEASURING AND CUTTING PROCESS
Measure Bore
Send Data
Measure Bore
Send Data
Final Cut
Precut
INTEGRATION
APP CONTROL Option 1
• Simple setup and operation • Adjustment in difficult-to-reach locations
With this control method the user needs to be present during the machining process to make the adjustments on the App (tablet or phone). The measurement may be done by probe or by hand (common micrometer) and the adjustments
need to be made by the user via the app to the EWA head, which will self adjust via the built-in drive and measurement method. This control method offers an introduction to the world of automatic fine boring without the need for complicated integrations
and can be used on multiple machines without the need for additional calibration. The boring system can adjust the fine boring size in hard-to-reach locations on very large machines up to a maximum boring diameter of 861mm.
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MACHINE CONTROL INTEGRATION Option 2
• Fully automated system • Lights-out manufacturing • Reduction of human error
This control allows operators to step away during the machining process. The machine tool code calculates adjustment values based on measurements from any tactile probe. These values are then communicated bi-directionally to
the industrial PC via Ethernet and Bluetooth ® , allowing the EWA head to self adjust using a built-in drive and measurement system. This option requires some machine integration and user training. The system can be integrated into
most modern machine controls— whether new or retrofitted—with the machine manufacturer‘s collaboration. These features reduce human error and make the system ideal for lights-out manufacturing.
SOFTWARE
The EWA-SYNC control software runs on Windows 7 or higher. An industrial PC is provided by BIG DAISHOWA. This software provides 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 through-hole antenna directly connected to the PC, and mounted inside the working area of the machine tool. The control software synchronizes the machining process with the automatic tool adjustment by sending information from the machine tool to the EWA and vice-versa.
ADDITIONAL FUNCTIONS • Semi-automatic control of the EWA via adjustment data in the software
• Detailed information on error codes (e.g. battery low, tool blocked, etc.) • Reading log file of the EWA tool • Installation support functions
• EWA tool configuration • System configuration
SUPPORTED CONTROL SYSTEMS
Control Manufacturer
Supported Control System
Catalog Number
Models
Fanuc
Controls with FOCAS2
EWA-SYNC-FAN-STD
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Heidenhain
All Systems with «Option18»
Heidenhain DNC, TNC640, TNC620, etc.
EWA-SYNC-HEID-STD
Machine Control Integration
Siemens
SINUMERIK with OPC-UA Server
SINUMERIK 1, SINUMERIK 828D, etc.
EWA-SYNC-SIEM-STD
Mazak
MAZATROL with API Option
EWA-SYNC-MAZ-STD
OSP-P100II, OSP-P200 and Newer OSP-P Controls
Okuma*
THINC-API
EWA-SYNC-OKU-STD
*Pending final validation. Market launch in 2024.
MAIN SCREEN ( UI )
Main screen with overview 1 Tool status with the maximum travel 2 EWA Tool settings including possibility of manual adjustment 3 Settings for the communication with the machine tool 4 Status of the machine tool incl. 5 Measured diameter of the probe & programmed diameter in the g-code 6 Error messages of the EWA systems 7 Operator settings
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6 7
1
2 3
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EWA FINE BORING SET Experience the ultimate in automatic boring with our innovative solution that combines flexibility, precision and safety. Designed to work seamlessly with any measuring probe, the system ensures the boring process is fully automated and within tolerance. With just three insert holders, you can cover a wide range of diameters, making it the perfect choice for efficiency and reliability in your operations.
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EWA 68 SET
SET CONTENTS ( Provided in Storage Case)
Catalog Number
Catalog Number
Qty.
EWA68-134CKB6-SET
Boring Head
EWA68-134CKB6
1
Insert Holders
ENH8-1T
1
ENH8-2T
1
ENH8-3T
1
Inserts
655.318 (TCGT-110204-M20C)
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BORING RANGES A wide selection of insert holders available to fit a variety of diameters.
EWA 68
Insert Holder
Ø (mm)
ENH8-1T
68-90
ENH8-2T
90-112
ENH8-3T
112-134
EWA68 with BR134-200-EWA-CKB6
Insert Holder
Ø (mm)
ENH8-1T
134-156
7
ENH8-2T
156-178
ENH8-3T
178-200
EWA68 with CB200-CKB6 (for Large-Diameter System)
Insert Holder
ENH8-1T Ø (mm)
ENH8-2T Ø (mm)
ENH8-3T Ø (mm)
ENH8-1T Ø (mm)
ENH8-2T Ø (mm)
ENH8-3T Ø (mm)
Slide
Position 1
Position 2
SLN200-270
200-222
222-244
244-266
235-257
257-279
279-301
SLN270-340
270-292
292-314
314-336
305-327
327-349
349-371
SLN340-410
340-362
362-384
384-406
375-397
397-419
419-441
SLN410-480
410-432
432-454
454-476
445-467
467-489
489-511
SLN480-550
480-502
502-524
524-546
515-537
537-559
559-581
SLN550-620
550-572
572-594
594-616
585-607
607-629
629-651
SLN620-690
620-642
642-664
664-686
655-677
677-699
699-721
SLN690-760
690-712
712-734
734-756
725-747
747-769
769-791
SLN760-830
760-782
782-804
804-826
795-817
817-839
839-861
• Other ranges available; contact the BIG DAISHOWA Engineering Team
EWA 68 SPECIFICATIONS
Wireless Communication
Bluetooth ® Low Energy
Ø68–134mm with Overlaps (3 Insert Holders) Up to Ø861mm with Bridge Tools
Adjusting Range
Adjusting Precision
±2 µm
Maximum Cutting Speed
300 m/min
Recommended Coolant Pressure
Max. 40 Bar
Battery
CR123
Battery Life
Approx. 10m of Total Adjustment
Adjusting Speed
Approx. .8mm/s
Communication Range
10m
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Cutting Stock Allowance
Max. .3mm/Ø
Wake-Up Function
Accelerometer (Tool ON with Movement or Rotation)
Blinking Green: Tool is ON Blinking Blue: Tool is Connected Blinking Yellow: Tool is Being Adjusted Blinking Red: Error OFF: Tool is in Stand-By
LED Indicator
HIGHER PERFORMANCE. GUARANTEED. Tool Holders | Boring Tools | Cutting Tools | Workholding | Tool Measuring (224) 770-2999 | bigdaishowa@us.bigdaishowa.com | bigdaishowa.com
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