In multi-function, multi-facet machining, the concepts now benefit from the latest CNC that enhances machine tool capabilities and the interface with the operator and/or production management.

Yamazaki Mazak's Integrex range is one of the most efficient methods of producing complex components in a single set-up. With the Integrex e-range Yamazaki Mazak has taken this concept to the next level by fusing Information Technology with Manufacturing Technology to deliver multi-tasking machines ideally suited to the machining of large workpieces. The Integrex series provides the user with a powerful multi-tasking machine tool platform from which to make full use of the machining flexibility that Yamazaki Mazak has created.

One of the key developments is the introduction of the Mazatrol Matrix control.

It is this new CNC system that enhances the capabilities of the machine and the interface between it and the operator and/or remote production management and control.

Features such as Intelligent Safety Shield would not be possible without the development of the Matrix control system.

Typical of the e-tower range is the new Integrex e-800V/5.

Designed for turning and milling large diameter workpieces on multiple faces, the e-800 makes full use of the tilting spindle and rotary table technology pioneered by Yamazaki Mazak.

The e-800V/5's powerful 22kW milling spindle can be positioned to provide vertical or horizontal milling capability; alternatively, it can be moved to any position within a 150 deg arc.

When used in conjunction with the 30kW rotary table, multi-facet machining becomes a straightforward proposition.

Components measuring up to 730mm wide by 1000mm high can be machined on five faces whether they require milling, drilling, turning or a host of other machining processes.

Differentiating the e-machines from the conventional Integrex is the addition of innovative functions to support multi-tasking machining.

This includes integrated factory management functions such as programming, material and tool stock control, remote alarm notification, maintenance information and scheduling, production control alarm, and generating production reports.

All of these functions can be used independently or as part of an advanced manufacturing cell using Yamazaki Mazak's Cyber Factory model.

Other developments across the Integrex range include Intelligent Thermal Shield, Intelligent Safety Shield and Active Vibration Control.

Intelligent Thermal Shield has been developed to minimise heat displacement, the machine units producing the minimum possible amount of heat during operation.

Additionally, there is automatic compensation for changes in room temperature.

As a result, machine heat displacement is less than 10 micron with a room temperature change of 8 deg C.

Intelligent Safety Shield highlights any possible collision points when any program is simulated on-screen prior to it being used to actually machine components.

However, Intelligent Safety Shield takes this protection several steps further with the machine being monitored when it is operated in manual mode for instance, during tool measurement with the Tool Eye or when changing inserts.

All machine movements are monitored by the Mazatrol MATRIX control, which moves the machine's 3D model simultaneously with the manual data inputs to check machine interference.

Should this occur, the axis movements are stopped immediately, preventing damage to the machine and avoiding costly downtime.

The third innovation is Active Vibration Control, which reduces vibration in all axes and results in improved accuracy and surface finishes.