High-precision automated fine boring from Big Kaiser

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The future of fine boring is being developed in Big Kaiser with the EWA system, an automatic fine boring tool that provides fully-automated machine tool operation without the need for a human operator. EWA makes fine boring more accurate, faster and less expensive, whilst enabling handling of multiple bore sizes and repeated bores, avoiding the need for time-consuming manual wear-out compensation.

The system doesn’t require to stop the machine tool to take measurements and to manually adjust the boring tool, saving time and also eliminating human factor and highly reducing the likelihood of having to scrap expensive workpieces due to human errors. In industries such as aerospace, the scrapping of a single workpiece can cost easily upwards of $50.000.

EWA can be used in three primary configurations: firstly, it can be operated as a standalone tool, controlled via a tablet with a wireless connection. Secondly, 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. Thirdly, 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.

Developing the system, Big Kaiser is working with Makino and other forward-looking organizations to make this level of integrated automation the new reality of Industry 4.0. The EWA system is based on Big Kaiser’s EWE digital fine boring heads and the EWN precision boring heads and is being developed entirely in-house.

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