Edumar Metaalbewerking is the pilot customer for the new Infinity platform from BMO Automation. Less than a year after the installation of the first module for pallet handling in the factory, the cell was expanded to include product handling and linked to a second CNC machine. The Infinity platform is a flexible automation platform that grows with the machining company and can be adapted to operational decisions. The Infinity platform recently won the Technishow Innovation Award.

Passing on know-how to customers

Edumar Metaalbewerking describes itself as a socially responsible company that not only works for its customers, but also works with its customers. This is probably due to the fact that both founders and owners, Eduard and Marius Wijlaars, can look back on a career at Philips. "We would like to pass on our own experience to our customers and show them how they can further optimize the production of their workpieces," explains Eudard Wijlaars.

Many years of experience with robotic cells

The two brothers bought their first robot back in 2006. "I was happy with it for three weeks, but not after that," says Eduard Wijlaars, recalling the early days of automatic loading of a CNC machine. The milling machine had processed the products on the 12 pallets within two hours. "I drove back to the company from home to clamp new workpieces. That's why I wasn't quite so happy with this solution after just a few weeks." Within a year, a robot with 30 pallet positions was purchased. And in 2012, Edumar bought the first BMO robot system. Today, Edumar uses several robot cells from BMO Automation. "We produce the contract products at weekends and overnight so that they don't clash with other orders. Our machines always run overnight and at weekends. We are processing more and more small quantities in a large variety, i.e. so-called 'low volume high mix'. Just a few years ago, we didn't dare to process individual pieces on such an automatic machine - today we do."

Wanted: A flexible solution for automation

At the beginning of 2022, Edumar received a large order to mill aluminum plates for a production hall in the semiconductor industry. It involved a large number of pieces measuring more than 600 mm square. Due to their size, they were not suitable for use in BMO's titanium cell. The two brothers realized that automation was required for an order of this size. Eduard Wijlaars: "Frank Biemans promised to find a solution. But we didn't just want to load the large panels, we also wanted to be able to mill smaller components unmanned in the new cell later on." A few months later, the supplier became a pilot customer for the new Infinity platform from BMO Automation, which was presented internationally at EMO 2023. The cell is characterized by its modular design. Additional storage modules can easily be added. The height of the standardized carriers for products and even tools, such as vices, is adjustable. This dynamic storage is controlled by intelligent algorithms: In the Infinity storage modules, the height for the carriers can be adjusted in steps of 5 cm, and this is done fully automatically based on the measured height during feeding by the operator. In this way, the storage modules dynamically adapt to the orders to be processed at night or at the weekend. "This makes it even easier for us to manufacture a wide variety of products unmanned," says Eduard Wijlaars, summarizing the advantages.

Reduce downtimes

BMO Automation controls production in the cell using its own job management software. With the Tool Life Management option, the software uses the operating hours to automatically assess whether the tool life is still sufficient for the planned production. If this is not the case, the operator is automatically warned during set-up. The software also reports if a particular vice is missing. "The smaller the batches to be milled, the more important this tool life management software is," says Eduard Wijlaars. "People make mistakes, software doesn't. It helps to avoid machine downtime. Once the operators have ticked off the entire list, they can switch on the machines with confidence." Eduard Wijlaars is still amazed at how easy the software is to use. For him, however, this is an absolute prerequisite. "The software should be as simple as possible for the operator. He doesn't necessarily want to program 9 axes or program a robot with a teach panel." However, Eduard Wijlaars does not want to give the impression that operators do nothing but press buttons. On the contrary: he and his brother are constantly challenging their employees. They invest a lot in further education and training. They also all create their own programs with hyperiMill. The level 3 apprentices (vocational training) are already learning to work with this CADCAM software. "When you create your own program, you recognize your mistakes and learn from them. The boys are now thinking much more about how best to mill workpieces and how to set up production correctly."

The Infinity platform can easily be set up to operate more than two CNC machines. Edumar deliberately keeps to two CNC machines, the Forte 65 and the Acura 85. According to Eduard Wijlaars, this is efficient enough. "Something can always go wrong at night and then four machines stand still when you have a line with four CNC machines. If you weigh up the cost of the robot against the cost of one machine, a cell with two CNC machines is a good solution, especially if we soon start working with the AMR." As soon as the new hall is finished, there will be a large rack for storage and a robot in front of it that will load the AMR to automatically supply the Infinity platform with materials, workpieces and soon also tools. This will make production even more flexible, and Edumar would in principle have to keep less stock of high-speed machines for repeat orders. However, Eduard Wijlaars does not intend to do this. "In quiet weeks, we produce for stock. When demand picks up, we can deliver from this stock and then have more time for rush orders. We are then more flexible."

Spindle efficiency an important criterion

For him, spindle efficiency is not the decisive factor, but the flexible automation solution from BMO Automation helps to keep spindle efficiency high. To illustrate this, he refers to a specific job in which the 3-axis machine processes strips. "For this, we produced a mold that fits 12 strips. It is in a fixed position in the Infinity cell. When we have an hour at night, we mill these 12 strips."

With a solution like the Infinity platform, automation is not rigid, but extremely flexible. Exactly what manufacturing companies need to be able to respond well to changing demand. "We don't encourage our employees to work harder, but rather motivate them to work smarter. I would prefer to have lazy people, because they let the machines and robots do the work," laughs the metal entrepreneur from the Netherlands. Given the constant increase in production, his 40-strong team certainly can't be described as lazy. But they are smart.