Customization and Flexibility in Modern Machine Tool Automation Systems

Modern machine tool automation has evolved over the last decade to adapt to growing complex needs for various applications throughout many industries. Customization and flexibility are essential to manufacturing today, and they are two components that we will see grow and shift as manufacturing continues to evolve. Mitsubishi Electric Automation is a leader in the CNC controls industry with over 50 years of experience in North America, and we are expanding into more roles within this market. We're analyzing customization and flexibility in machine tool automation systems and how they might evolve over the next few years.

How Customization and Flexibility Started in Manufacturing

Although customization and flexibility in manufacturing are huge components today, they weren't always like this. Many small shifts within the manufacturing industry made this happen, and it is now something that we see consistently. To start, shorter product lifecycles meant that manufacturing was amping up and companies ended up producing more products, faster, to meet this lifecycle demand. On top of this, many companies started introducing more variety into their product offerings. This meant that they'd need to be manufacturing many different types of products simultaneously within one facility. Lastly, there was a huge need for these companies and manufacturers to meet this demand quickly. As these changes continued, there was a need for scalable solutions to be put in place for diverse manufacturing needs, and this is where flexibility and customization became important components.

What is Computer Numerical Control?

Computer Numerical Control, or CNC, is a method that automates machine tools using software programmed with instructions that control the movements and operations. These machine tools can include mills, lathes, routers, and grinders, which are controlled by a computer instead of manually operated by a person. These coded instructions tell the machine to perform certain tasks, like drilling, cutting, or shaping, with consistency and accuracy.

Key Features of CNC Systems

• Automation: The most prominent feature of these systems is that once they're programmed, they don't need much manual intervention, and they stay automated throughout the entire manufacturing process.
• Precision: These systems are much more precise than a manual movement would be, and they are consistent from part to part while working quickly.
• Customization: The systems can be customized for different products or features throughout the manufacturing process.
• Efficiency: They help to reduce waste, increase the speed of production, and improve consistency throughout the manufacturing process.

Flexible Systems: Independent vs Rack-Based CNC

CNC systems are very flexible and customizable, but the two main types, independent and rack-based, offer different functions. Based on your particular manufacturing needs, you might find that one will work better for you than the other. Here's a breakdown of the differences between the two so you can determine which one might be best for your needs.

Independent CNC Systems

Independent CNC systems are ideal for standalone applications that need this level of precision, customization, and flexibility. The protocol options for this system include EtherNet/IP (EIP), PROFINET, and Modbus. The main benefits of this system include the ease of integration into your manufacturing lineup, simplicity of learning and utilizing it, and a lower carbon footprint than many similar alternatives.

Rack-Based CNC Systems

Rack-based CNC systems are typically integrated into a PLC rack for seamless factory automation, making manufacturing even more automated and easier. This system supports many different industrial protocols such as CC-Link IE TSN, EIP, PROFINET, Ethernet, and many more. The main benefits of this system include unified control throughout the system, real-time data exchange that can be monitored, and a future-ready architecture that will stand the test of time.

Benefits of a Flexible Automation Approach

There are many benefits to a flexible automation approach. We're going to lay out some of the top benefits so you can get an idea of the advantages you may see when you include a flexible automation approach in your manufacturing.

Reduced Downtime and Easier Upgrades

This type of system has a design that makes upgrading very easy without having to rework the entire system setup. It also allows seamless software and hardware integration, which can minimize production disruptions during upgrades or maintenance on the system.

Enhanced Scalability

Manufacturers can start small with this system and add capabilities without overwhelming their entire system. Mitsubishi Electric, in particular, supports both independent and rack-based systems, which makes it much easier to scale. You can integrate additional axes, tools, or machines into the existing system easily.

Easier Integration with 4.0 Initiatives

Having multi-protocol support for protocols such as EIP, CC-Link, Ethernet, and PROFINET makes it much easier to connect with other systems and cloud platforms. Real-time data from machines can also be fed into monitoring tools to optimize production and enable predictive maintenance, which is an important part of manufacturing today.

Improved Return on Investment

The ROI from these flexible systems is improved by higher uptime and productivity. There is also a lower total cost of ownership due to the future-reach architecture that will adapt to technological changes to come in the future, which makes this investment even more worthwhile.

Greater Customization for Unique Production

Manufacturers can tailor control systems to their specific needs, workflow, and materials that they handle. This improves both efficiency and product quality. Customizable interfaces make it much easier for operators to manage machines intuitively.

How Mitsubishi Electric is Committed to These Systems

At Mitsubishi Electric, we are investing more in these systems that we know will help manufacturers and stand the test of time in the future. Customization and flexibility are two top components of the CNC systems, and we know that they play a critical role. As a trusted partner for manufacturers, we are here to support during evolving challenges and as the manufacturing business continues to grow as an industry. With CNC systems, there is no wrong answer as they can be a huge asset to your business and ultimately can bring a whole list of benefits to your company, which will help you to scale, increase productivity and efficiency, and allow you to be future-ready. If you are interested in learning more about tailored CNC systems and want to see if it's right for you, contact us at Mitsubishi Electric, and we can get you started.

Want notifications for new Blogs, White Papers, Case Studies & Webinars?

Return to Blogs

How Can We Help You?

Contact Sales

Request a Product Quote

Join Us

Contact Support