三晃工具 List of Products and Services

The complexity of CAD/CAM operations in long-length processing increases reliance on skilled workers in many workplaces, becoming a bottleneck in production lines. In particular, reading drawings, modeling, and ultimately creating tool paths often require years of experience and intuition. Our in-house developed NC processing machine offers a unique software called "Zeros" that bypasses this complex CAD/CAM process. Zeros' intuitive interface is designed to directly utilize drawing information, allowing on-site personnel to easily generate and modify processing programs without needing to be skilled operators. This establishes a system for creating processing data with stable quality without relying on specific individuals, fundamentally solving the issue of dependency on certain personnel. *For more specific solutions and case studies, please download our materials for further information.

In systems that utilize conventional general-purpose NC, even with CAD/CAM data, it was necessary to spend a tremendous amount of effort and time defining coordinates and manually setting detailed processing conditions in order to create the final processing program. This has been a major factor in long lead times. Our NC automates the complex coordinate calculations and the definition process of processing conditions through our unique programming software. By simply inputting the necessary key information, the program is generated instantly. This dramatically reduces the time operators spend on programming, making it theoretically possible to approach "zero." As a result, setup time is significantly reduced, maximizing production throughput. *The full details of the mechanism that dramatically improves productivity are explained in this document.

In long-length processing, detailed design changes and on-site adjustments occur frequently. In traditional systems, these changes are sent back to the CAD/CAM department, causing a cumbersome loop of re-modeling, re-running the post-processor, and re-outputting the NC program. Our proprietary NC processing machines combined with Zeros software eliminate this inefficient work loop. On-site NC allows for parameter adjustments without waiting for modifications from the CAD/CAM side. This enables immediate responses to design changes and sudden specification adjustments, allowing for smooth operations without halting the processing of long materials. *You can check the details of the software that enables on-site driven changes in the materials available now.*

In machining equipment equipped with general-purpose NC, it is essential to adjust the "post-processor" to tailor the data output from CAD/CAM to the specifications of each NC machine, as well as to manually correct the final code. This can lead to mistakes and delays in work. Our NC system, developed in-house, directly outputs optimized data from our proprietary programming software to the NC machining equipment. Since the intermediate process of post-processing is no longer necessary, there are no issues or adjustments related to the output data. This significantly shortens the lead time from data creation to the start of machining and achieves standardization of machining preparation. *Please check the documentation for the technical backing that frees you from the stress of post-processing.

If the traceability of processing data is weak, there is a high risk that outdated or incorrect data will be used in the processing on-site. This is especially true for expensive materials like long-length materials, where a single mistake can lead to significant costs and risks of line stoppage. Our NC processing machine offers an innovative system called the "two-dimensional code linkage function," which operates processing data as a unique two-dimensional code. Operators can simply scan the two-dimensional code attached to the paper work instructions or the workpiece to load the correct processing data into the NC machine. This physically eliminates data discrepancies and perfectly maintains synchronization between the on-site and design departments. *We provide a detailed explanation of the traceability management system that reduces the risk of data errors to zero in our materials.

One of the biggest challenges in the manufacturing site is the concentration of CAD/CAM knowledge and skills among skilled workers. As this personalization progresses, there is a constant risk that the entire production line will become a bottleneck during personnel transfers or vacations, leading to operational stagnation. The Zeros software embedded in our in-house developed NC has an intuitive operating system that does not require advanced knowledge of CAD/CAM. By simply inputting the necessary information for processing (dimensions, pitch, etc.) without being aware of complex G-code, data is generated, allowing new employees and those without CAD/CAM experience to create and modify processing programs in a short period, thus promoting multi-skilled workers on the shop floor. *Please refer to the materials for details on the approach of systematizing the skills of skilled workers and sharing knowledge.

In processing sites that handle expensive materials like long materials, operator mistakes or data entry errors can directly lead to significant losses in the form of material damage or machine damage. The more manual programming and coordinate setting involved, the higher the risk of human error. Our NC system provides a function to thoroughly verify and simulate data on the NC machine side before processing begins. Through our unique programming logic, it detects impossible values or coordinate specifications in advance and warns the operator. This significantly reduces the risk of damage to expensive materials due to data errors, creating an environment where long material processing can be entrusted with peace of mind. *You can view details of the safety features that prevent processing defects and the effects of implementation in the provided materials.*

To master the operation of CAD/CAM software, specialized knowledge and long-term training are required. This high educational cost has become a significant obstacle to new hiring, especially in the manufacturing industry, where there is a severe shortage of personnel. Our core Zeros software for NC machining is specialized in "inputting the information necessary for processing," eliminating the need to learn the complex modeling and tool path creation that traditional CAD/CAM systems required. As a result, the training period for new employees can be dramatically shortened, allowing them to handle data creation and modification tasks on-site within a few weeks. This frees companies from the burden of expensive CAD/CAM educational investments and significantly reduces training costs. *We provide materials that introduce specific operational methods that can be used immediately on-site, shortening the training period.*

The length of setup time in long material processing directly leads to a decrease in production efficiency. In particular, the series of steps involved in creating processing data, transferring it to the NC machine, and then verifying the data content on-site becomes increasingly inefficient as the lot size increases. Our NC system not only reduces data creation time through programming-free processes but also enables high-speed transfer of processing data via two-dimensional codes, simplifying the data verification process on-site. As a result, the time from data creation to setup on the NC machine can be reduced to less than half of the conventional time. Reducing setup time directly improves production efficiency in long material processing. *For details on the system that realizes innovation in the entire setup process, please refer to this document.*

As market demands become stricter, the manufacturing industry is required to respond flexibly and quickly to short lead times. However, traditional systems that go through complex CAD/CAM processes tend to have longer lead times when dealing with sudden orders or specification changes. Our in-house developed NC machining equipment allows for immediate adjustments and reflections of parameters directly on the NC without the need to return to CAD/CAM, even when design changes occur. This on-site correction capability minimizes the time required for data creation and adjustments after design changes, demonstrating overwhelming responsiveness to sudden additional processing or short lead time orders. This enables the establishment of a production system that can quickly respond to market changes. *For details on the technology that enables flexible on-site responsiveness, please download the materials and check.

General-purpose NC programs often leave uncertainty about whether the output data will function correctly on NC machines due to issues with post-processor adjustments and compatibility across different models. As a result, "trial cutting," which consumes time and materials, has become essential. Our NC system is fully integrated with our proprietary programming software and in-house developed NC, ensuring that the output data is always optimized for NC machining. This guarantees data integrity and eliminates the need for extensive trial cutting or verification work. We provide the "confidence" to transition to actual processing on-site, reducing verification time to zero. *Please refer to the materials for the mechanism of data linkage that achieves reliability without the need for trial cutting.

In long-length processing, a single data error during machining can lead to the damage of expensive workpieces spanning several meters, as well as trigger a chain reaction of risks such as delays or stoppages in the entire production line. Therefore, data management and program accuracy are extremely important. Our NC machining machines significantly reduce data errors caused by human error through the automation of data creation and immediate data verification functions on-site. Furthermore, by thoroughly implementing data operations using two-dimensional codes, we completely prevent machining execution with outdated data. This rigorous risk management system brings the risk of long-length material damage and line stoppage due to machining data errors close to zero. *We will provide detailed materials on the risk management that supports the stable operation of your long-length processing line.

In traditional file-based data management, even for the same part's machining data, numerous files exist with different versions and revisions due to design changes and fine adjustments, making it cumbersome to find new data on-site. Our NC system centrally manages machining data in a database and restricts data provision to the site via two-dimensional codes. This system ensures that only the latest version of the data is loaded onto the NC machining machines on-site. It frees users from complex file management and completely eliminates the time spent searching for data or checking versions. *The system and benefits of the database integration that revolutionizes data management are explained in detail in this document.*

The transfer of NC programs via the network tends to be unstable due to various factors such as security restrictions, network delays, and poor cable connections. Failures or delays in data transfer are significant stress factors that can interrupt on-site work. Our NC solution employs a unique architecture with high compatibility with IT systems. In addition to wired LAN connections, we provide physically stable data link methods such as two-dimensional code integration, minimizing the risks associated with network dependency. This enables the rapid and reliable transfer of large volumes of processing data to NC machining machines. *We have materials introducing a stable data integration system that is resilient to network troubles.

When the information that the on-site operator can confirm on the NC machine panel is limited, there is a tendency for delays in detecting data errors or unintended behaviors, leading to mistakes being discovered after the processing has begun. Our self-developed NC processing machines provide an interface that allows for a visual and detailed confirmation of the processing program's content on the NC machine's operation panel, thanks to our unique software. Since the processing route, coordinates, parameters, and more can be directly checked on-site, operators can detect final mistakes just before starting the processing and prevent them in advance. This feature enhances safety and reliability. *Please refer to the materials for details on the user interface that enables on-site data confirmation.

When operating multiple NC machining machines from different vendors, post-processing for CAD/CAM tailored to each model and conversion tasks to different data formats constantly arise, significantly reducing operational efficiency. Our NC machines are developed in-house, using our proprietary programming software (Zeros) as a common platform. The data output from this software is guaranteed to be compatible across all models and generations of our NC machining machines. This completely eliminates conversion and adjustment tasks in data operations between different models, achieving standardized data management. *Details of our strategy to eliminate data format barriers and establish a unified platform are explained in the accompanying materials.

In the processing of long workpieces, defining the coordinates for machining positions over several meters becomes extremely complicated. In traditional NC programming, this complex coordinate calculation has been a major factor contributing to errors and increased work time. Our NC machining system is equipped with a parameter input function specifically designed for long workpiece processing. Operators only need to input intuitive information such as the distance from the end of the long material, pitch, and the number of holes, rather than complex absolute coordinates, and the system automatically defines the coordinates for all machining positions. This eliminates the complexity and errors in defining machining positions for long workpieces. *Please check the documentation for programming logic optimized for long workpiece processing.*

Every time a long workpiece is set, resetting the origin (zero point) of the NC machine and the position of the jig, and aligning it with the coordinates in the program, results in significant setup time loss. The more manual work involved, the higher the risk of errors occurring. Our NC machining machines are equipped with an automatic reference alignment function that understands the characteristics of long workpiece processing. By utilizing specific detection points, we minimize the fine adjustments of the jig position and the resetting of reference points that occur every time a workpiece is set, allowing the program to automatically apply offsets. This reduces setup time and achieves standardization and improved accuracy in operations. *The high-precision positioning technology that enables the automation of setup is explained in detail in this document.

Conventional CAD/CAM simulations are often conducted in ideal environments, and may not accurately reflect the details of setups such as the jigs used in actual work sites, workpiece deflection, and clamp positions. This discrepancy creates the need for trial cuts. Our Zeros software for NC machining is designed to easily incorporate actual jigs and setup information for long-length processing into the system, enabling the creation of data that reflects the physical constraints of the work environment. As a result, it minimizes the gap between desktop simulations and actual machining environments, maximizing confidence before starting the machining process. *Please refer to the materials for details on the data creation flow that reflects the reality of the worksite.

In the processing of long materials, there are many repetitive, standardized tasks such as drilling and cutting at regular intervals. Nevertheless, traditional programming methods still require manual adjustment and input of parameters, even for simple repetitive tasks. Our NC system offers a "pattern repetition function" specifically designed for long material processing. Once the initial pitch and number of repetitions are defined, the system automatically programs all remaining processing positions. This completely eliminates the need to manually input the same hole pitch or processing pattern each time, dramatically improving the programming efficiency of NC machines in repetitive processing. *We provide documentation introducing efficient programming features that free you from repetitive tasks.