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Product category: Control systems, DROs, etc, for machine tools
News Release from: Yamazaki Mazak UK | Subject: Mazatrol Matrix
Edited by the Manufacturingtalk Editorial Team on 28 June 2006

Latest machine tool CNC is even easier
to use

Latest machine tool control system is even easier and quicker to use than its predecessors and delivers elements that take machine control and machining to new efficiency levels.

It comes as no surprise that Yamazaki Mazak's 6th generation control system, the Mazatrol Matrix, is even easier and quicker to use than its predecessors However, as you would expect from one of the pioneers of conversational programming Matrix is about more than making the control/operator interface more effective: it delivers elements that take machine control and machining to new levels of efficiency

While the headline figures may be the 16 million pulses per revolution encoders, 64 bit twin-engine processor and sub-micron input and Nano control, within Matrix are five key elements that distinguish it from other control systems currently available.

These are: Intelligent Safety Shield; Virtual Machining; Active Vibration Control; Intelligent Thermal Shield; and new Mazatrol machining functions.

So, what are these features and, more importantly, what are the benefits of them? Intelligent Safety Shield provides the user with active collision monitoring, whether the machine is used in manual or full CNC mode.

This highly sophisticated system uses a solid model of the machine, tooling and workholding to create 'no go areas'.

If these areas are breached during operation, the control overrides the input feed movements and brings the machine to a stop in controlled conditions.

The key benefit of this system is the virtual elimination of collisions and the consequent downtime and cost associated with them.

Another, more subtle, benefit is the ability to prove out programs faster and with a higher degree of confidence, secure in the knowledge that any potential conflicts that have not been picked up during any pre-process checks will be identified by the Matrix control.

The end result is higher machine utilisation and productivity.

Virtual Machining is an extension to Intelligent Safety Shield in that it monitors potential collision points during the creation of the NC program.

By integrating Virtual Machining into the programming operation the time to complete the entire process is greatly reduced.

One of the issues facing machine users, particularly where high speed and high agility is required, is that of vibration.

Machine vibration due to high velocity multiple-axis movements can have a negative effect on component quality and result in extended cycle times.

Mazak has addressed this with the development of Active Vibration Control, a function that is possible due to Mazak's use of fine resolution encoders and more powerful servo drives.

As a consequence Matrix is able to monitor and modify axis movements 'on the fly', something that is of greatest importance on changes of direction.

The resulting reduction in vibration for high accuracy positioning allows much higher quality surfaces to be produced at standard feed rates; alternatively, if surface finish can be sacrificed, to a degree, even higher feed rates can be employed to significantly reduce cycle times.

A further benefit is the increase in tool life due to a reduction in tool wear and edge breakdown that are a common problem when vibration is present on the machine.

Another major area of concern to machine tool users and builders is heat, or more particularly heat dissipation and control.

Mazak has approached this particular problem from two directions when creating its Intelligent Thermal Shield within the Matrix control.

The first is to look at the design elements of machines and identify any potential localised areas of heat build up and eliminate them where possible.

The second is to channel heat away from the machine area.

Mazak has linked the machine design to new software developed specifically for the Matrix control.

"This software recognises how machine parameters can change under different temperature conditions," said Lawrence McCann, deputy applications manager.

"The control is then able to compensate for these conditions and maintain accuracy over extended periods of operation.

The real benefit is that machines can be left unmanned for longer, quality and accuracy remain constant, and productivity is improved due to the lack of machine downtime for checking and resetting offsets." The last of the five key features is the new programming functions - in excess of 100 - that have been created for the Matrix control.

These functions assist in the programming of the machine by simplifying the process and improving cycle times.

Typical of these is the Mazatrol Mill-Turn cycle, which is extremely effective when 'rough cutting' difficult to machine materials such as aerospace alloys.

Both the milling tool and workpiece rotate for this operation, providing improved chip control.

And as multiple inserts are used for cutting instead of the single insert that is the norm for turning applications, the effective cutting force is reduced.

A higher feedrate can then be used, which extends the cutting life of the inserts and enables unmanned operation to take place over extended periods of time.

Similarly, the addition of the ability to machine on two spindles and two stations simultaneously is crucial in terms of multi-function machines as it is now possible to conversationally program the independent upper tool stations and bottom turret while monitoring all of the movements with Intelligent Safety Shield.

This is a major step forward for this technology.

So, having looked at these five key features of Mazatrol Matrix, what about those headline figures alluded to earlier.

All of them are in place to help manufacturing companies achieve higher productivity, improved quality and consistency.

With this 6th generation of Mazatrol control users have the capability to control nine axes, five simultaneously, with high accuracy machining ensured by a sub-micron (0.0001mm/0.00001in) minimum program increment for both Mazatrol conversational and EIA/ISO programming.

The new control's enhanced conversational capability caters for even more complex shapes, while the new system's calculation capability also delivers high-speed machining, even with sub-micron program commands.

The latest in pulse encoders on each linear axis contribute to a high quality surface finish by generating 16 million pulses per revolution - 16 times faster than the previous system.

Surface finish is further enhanced by Quadrant Spike Compensation, which minimises axis 'slip-stick' during machining operations such as circular interpolating.

To deliver this high level performance the Mazatrol Matrix incorporates a 64-bit 'twin-engine' processor to cope with the huge amounts of data generated during high-speed, high-accuracy machining.

The maximum vectoral feedrate available for machining complex surfaces is, in fact, four times faster than the standard specification of the previous CNC system.

And, of course, part-programs can be written and then checked off-line for machine and tool interference and downloaded easily to the Mazatrol MATRIX control via a network for convenient program management and high efficiency operation. Request a free brochure from Yamazaki Mazak UK ...

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