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Abacus Advances Compact Spinning Machines with HIWIN Linear Technology
New Premo 300 Nova combines compact design, high precision and heavy-duty HIWIN guides for efficient metal forming.
www.hiwin.com
Application Areas: Sheet Metal Forming, Tool and Machine Construction
Industry Sectors: Special-Purpose Machinery Manufacturing
Abacus Maschinenbau GmbH, a specialist in custom machinery for sheet metal forming, recently developed the Premo 300 Nova, a spinning machine engineered for the production of rotationally symmetrical hollow bodies. Recognizing an industry need for equipment capable of handling smaller components without the massive footprint and high investment costs of traditional extrusion systems, the company focused on building a highly compact and modular unit. To achieve this, Abacus Maschinenbau integrated high-performance linear technology, roller guides, and integrated measuring systems from HIWIN to ensure that the significantly reduced machine dimensions did not compromise operational precision or stability under severe process forces.
Market Demands and Equipment Sizing
Traditional extrusion machines deliver high output but are frequently oversized for manufacturing smaller components, leading to excessive space requirements and disproportionate investment risks. Manufacturers relying on manual pressing processes or operating large forming machines with high hourly rates required a scaled-down, automated alternative. The primary engineering challenge for Abacus Maschinenbau was to safely manage heavy process forces within a strictly confined space. During operation, the machine gradually forms flat sheets into rotationally symmetrical bodies using rotating spinning rollers. This process subjects the machine's mechanics to high, impact-like, and pulsating forces. Consequently, the mechanical framework and internal guide systems had to maintain absolute rigidity to prevent structural deformation.
Efficiency and Automation Goals
The development objective was to create an energy-efficient machine that facilitated the transition from manual metal forming to CNC-controlled automation. Key goals included maximizing process reliability, ensuring consistent component quality despite fluctuating force peaks, and simplifying the user interface to minimize operator training periods. Furthermore, the company sought to replace traditional hydraulic setups with precise servo motor technology to enhance overall energy efficiency, adaptability, and modularity, allowing for customer-specific adaptations such as additional Z-axes.
Implementation of Heavy-Load Roller Guides
To address the physical constraints and high structural demands, Abacus Maschinenbau deployed the HIWIN UR series, a generation of heavy-load roller guides designed specifically for tool and special-purpose machine construction. Unlike standard recirculating ball systems, this technical solution utilizes rollers as rolling elements. The line contact between the roller and the track enables the mechanical absorption of significantly higher loads with minimal elastic deformation. In addition, the system features a secondary, independent magnetic measuring system where the measuring tape is protected within the rail and the encoder is mounted directly on the block. Precision ballscrews complete the mechanical assembly to provide backlash-free power transmission and smooth axis movements.
Structural Rigidity and Safety Considerations
The roller guide system was selected primarily for its combination of rigidity, load-carrying capacity, and precision during highly dynamic processes. The integration of an internal magnetic measuring system replaced previous external tape or cable pull mechanisms, which are mechanically sensitive and pose safety hazards, particularly on suspended axes. Derk Weber, Managing Director of Abacus Maschinenbau GmbH, noted the importance of this configuration: "The integrated solution is robust, elegant and significantly enhances the machine’s functional safety." Furthermore, the supplier’s reliable delivery parameters, direct technical support, and the provision of a stable supply chain heavily influenced the procurement decision.
In-House Engineering and Supplier Collaboration
The design and sizing of the linear guides were executed entirely in-house by Abacus Maschinenbau. This internal engineering process was supported by the linear technology supplier through direct technical dialogue, sizing tools, and product configurators. The collaboration ensured that application-specific requirements for heavy-load processes were accurately met, particularly during the complex integration of the roller guide components into the confined machine footprint.
Quantifiable Load Capacity and Service Life Improvements
The integration of the advanced roller guides resulted in a highly rigid system capable of maintaining tight process stability during continuous, fluctuating force peaks. Mechanically, the selected UR series guides deliver up to 34% higher static load capacity and up to 19% higher dynamic load capacity compared to previous linear guide generations. These technical enhancements yield an extended service life for the guide elements of up to 70%, driven by optimized roller geometry and uniform force distribution within the block. By simultaneously shifting to servo motor technology, the manufacturer successfully eliminated the reliance on hydraulic power, delivering precise, energy-efficient operation within a significantly reduced facility footprint.
Edited by Natania Lyngdoh, Induportals Editor, with AI assistance.
www.hiwin.com
Industry Sectors: Special-Purpose Machinery Manufacturing
Abacus Maschinenbau GmbH, a specialist in custom machinery for sheet metal forming, recently developed the Premo 300 Nova, a spinning machine engineered for the production of rotationally symmetrical hollow bodies. Recognizing an industry need for equipment capable of handling smaller components without the massive footprint and high investment costs of traditional extrusion systems, the company focused on building a highly compact and modular unit. To achieve this, Abacus Maschinenbau integrated high-performance linear technology, roller guides, and integrated measuring systems from HIWIN to ensure that the significantly reduced machine dimensions did not compromise operational precision or stability under severe process forces.
Market Demands and Equipment Sizing
Traditional extrusion machines deliver high output but are frequently oversized for manufacturing smaller components, leading to excessive space requirements and disproportionate investment risks. Manufacturers relying on manual pressing processes or operating large forming machines with high hourly rates required a scaled-down, automated alternative. The primary engineering challenge for Abacus Maschinenbau was to safely manage heavy process forces within a strictly confined space. During operation, the machine gradually forms flat sheets into rotationally symmetrical bodies using rotating spinning rollers. This process subjects the machine's mechanics to high, impact-like, and pulsating forces. Consequently, the mechanical framework and internal guide systems had to maintain absolute rigidity to prevent structural deformation.
Efficiency and Automation Goals
The development objective was to create an energy-efficient machine that facilitated the transition from manual metal forming to CNC-controlled automation. Key goals included maximizing process reliability, ensuring consistent component quality despite fluctuating force peaks, and simplifying the user interface to minimize operator training periods. Furthermore, the company sought to replace traditional hydraulic setups with precise servo motor technology to enhance overall energy efficiency, adaptability, and modularity, allowing for customer-specific adaptations such as additional Z-axes.
Implementation of Heavy-Load Roller Guides
To address the physical constraints and high structural demands, Abacus Maschinenbau deployed the HIWIN UR series, a generation of heavy-load roller guides designed specifically for tool and special-purpose machine construction. Unlike standard recirculating ball systems, this technical solution utilizes rollers as rolling elements. The line contact between the roller and the track enables the mechanical absorption of significantly higher loads with minimal elastic deformation. In addition, the system features a secondary, independent magnetic measuring system where the measuring tape is protected within the rail and the encoder is mounted directly on the block. Precision ballscrews complete the mechanical assembly to provide backlash-free power transmission and smooth axis movements.
Structural Rigidity and Safety Considerations
The roller guide system was selected primarily for its combination of rigidity, load-carrying capacity, and precision during highly dynamic processes. The integration of an internal magnetic measuring system replaced previous external tape or cable pull mechanisms, which are mechanically sensitive and pose safety hazards, particularly on suspended axes. Derk Weber, Managing Director of Abacus Maschinenbau GmbH, noted the importance of this configuration: "The integrated solution is robust, elegant and significantly enhances the machine’s functional safety." Furthermore, the supplier’s reliable delivery parameters, direct technical support, and the provision of a stable supply chain heavily influenced the procurement decision.
In-House Engineering and Supplier Collaboration
The design and sizing of the linear guides were executed entirely in-house by Abacus Maschinenbau. This internal engineering process was supported by the linear technology supplier through direct technical dialogue, sizing tools, and product configurators. The collaboration ensured that application-specific requirements for heavy-load processes were accurately met, particularly during the complex integration of the roller guide components into the confined machine footprint.
Quantifiable Load Capacity and Service Life Improvements
The integration of the advanced roller guides resulted in a highly rigid system capable of maintaining tight process stability during continuous, fluctuating force peaks. Mechanically, the selected UR series guides deliver up to 34% higher static load capacity and up to 19% higher dynamic load capacity compared to previous linear guide generations. These technical enhancements yield an extended service life for the guide elements of up to 70%, driven by optimized roller geometry and uniform force distribution within the block. By simultaneously shifting to servo motor technology, the manufacturer successfully eliminated the reliance on hydraulic power, delivering precise, energy-efficient operation within a significantly reduced facility footprint.
Edited by Natania Lyngdoh, Induportals Editor, with AI assistance.
www.hiwin.com
