Set up like in the race, produce like a champion

A look at motorsport illustrates the principle. Races are not only decided on the track, but also in the pit stop. There is no room for improvisation here. Tools are ready, processes are defined, every action follows a clear plan.

In practice, this structure is often lacking. Tools are only changed in the work area, heavy holders are manoeuvred past cutting edges, clamping devices are released with a great deal of force, turning a planned tool change into an unplanned machine downtime.

This is precisely where EWS.Ready Safe and Go comes in - not as a single product, but as a holistic concept comprising hardware, software and organization.

The starting point is always the range of parts. Machining operations are analyzed and systematically arranged, and the turret loading is clearly defined. Frequently required machining operations such as external turning, parting off or solid drilling remain permanently in multiple holders on the turret. Changing machining operations are carried out via the standardized EWS.Varia interface. The turret thus becomes an integrated tool magazine.

Not every turret position is intended for quick change. EWS therefore makes a consistent distinction between permanent stations and flex stations. Varia is used specifically where changes are actually made - for example with driven tools or internal turning - supplemented by stable permanent stations for constant machining operations.

The actual set-up work is shifted out of the work area. Changeable inserts are set up, preset and measured externally to the machine. For clear assignment, prepared tools are stored in a structured manner in staging systems and identified using tool tags according to a standardized labeling logic. While the machine is producing, the next tool change is already fully prepared.

The changeover on the machine itself is carried out with safe one-handed operation - with simple handling and significantly increased safety for the operating personnel.

The effect is measurable, turning a time-consuming, error-prone set-up process into a calculable tool change. Depending on the machine and initial situation, changeover times can be reduced from several minutes to around 20 seconds - comparable to a professional pit stop.

Tool-Finder and 3D-Assistants make it possible to plan turret configurations in advance, exclude collisions and use tool data right through to the CAD/CAM system. Decisions are no longer made at the machine, but in advance. Machine-specific turret templates go one step further. In cooperation with machine manufacturers, complete turret configurations are developed, checked by EWS application engineers and made available in the web store. Users thus receive reliable setup concepts without having to do their own design work.

EWS supports users from analysis to implementation. The concept can be used across all industries, from classic mechanical engineering and medical technology to aerospace and high-growth fields such as robotics, and is also suitable for existing machines.

This turns an unplanned standstill into a controlled pit stop.

And this is where the race is decided.