Overview of the advantages

The benefits of Alphamoduli in all technologies and process steps.

Here, you can see the advantages and functions that Alphamoduli offers for all potential technologies and process steps. The advantages are assigned to the corresponding automation levels in your operation.

You can find more information about the automation levels here:

Select the technology:

CAD/CAM import

In all automation levels

Automatic creation of orders, parts and programs based on design data
Automatic transfer of NC files, eroding positions, QA measuring points and design drawings
No more transmission errors, also ensuring identical naming in design and production
Paperless production

Work preparation

In all automation levels

Completion of missing information from the CAD/CAM import
Imported data can be changed manually, intuitively, quickly and easily – no new data import required
Quick, easy creation of repair orders
Definition of sequences and priorities

Setup

In all automation levels

Job list for order backlog visualisation
Provision of production documents
Manual record of setup times

Identification

Individual machine automation,
entire process automation

No errors caused by confusing parts, thanks to unique identification of electrodes and components
Chaotic magazine equipping possible – eliminates the risk of places being confused during manual mounting
Transparency – the system ensures that you can always see which magazine a part is located in
Option to display parts information by scanning the RFID chip

Pre-setting

In all automation levels

Manual pre-setting of electrodes and workpieces on a CMM for all production technologies and transfer of the offset data in a neutral format for all machines
Automatic pre-setting based on manually learned pre-set electrodes (in the case of multiple identical electrodes)
Automatic pre-setting of electrodes based on the electrode information transferred from the CAD system
“Grid pre-setting” for multiple identical components on one pallet

HSC electrodes and hard milling, wire-cut EDM, laser machining

Data automation

Drastic improvements in available machine capacity with external setup
Save time thanks to convenient pre-setting on the CMM
Multiple NC machining processes can be combined into a main program if multiple chucks are used on the machine ➔ increased run time
Even older machines and control systems, for which automation is not technically practical, can be upgraded

Individual machine automation

Automatically transmit jobs to the control system
Automatically start jobs on the control system
Automatically record process times
Review tool availability in the internal tool magazine
Record machine statuses and faults
24/7 operation: Process multiple jobs by automatically switching parts in and out (only in combination with a handling system)

Entire process automation

24/7 operation: Process multiple jobs by automatically switching them in and out
Reduce lead times through parallel processing across technologies
Minimise manual parts handling using joint magazines for multiple machine tools
Outstanding flexibility as sequences and priorities are easy to adjust
Maximum transparency

Cavity sinking

Data automation
such as HSC, additionally:

Creation of the EDM program in the machine manufacturer-specific editor
Import the EDM program framework, including eroding positions, based on data from CAD (only in combination with CAD data import) ➔ no more transmission errors

Individual machine automation
such as HSC, additionally:

Interruption point: When a program is interrupted or stopped, we remember the stage at which this occurred, so that the program resumes from this point when restarted
The actual spark gap (measured on the CMM) on the EDM machine can be taken into account
Workpiece offset data can be transferred from the machine to the database
Simple undersize or depth correction, without the EDM program needing to be changed (ZK EDM only)

Entire process automation
such as HSC, additionally:

As soon as the first electrode in an order is finished, erosion can begin ➔ reduces lead time
Parts status is reviewed (ready for erosion) before switching in
Automatically start a job that has been previously interrupted due to a missing electrode (ZK EDM only)

Cleaning

Individual machine automation

Part-specific cleaning programs possible

Entire process automation

Automatic parts cleaning after machining on machine tools (prerequisite for automatic pre-setting and QA measurement) ➔ significant time savings
Simultaneous use in two handling systems possible

QA measurement

Data automation
Suitable for all machining technologies:

QA measurement based on 3D data from the CAD system
Best fit possible
Actual spark gap can be determined and taken into account in the EDM process
OK/NOK message with measurement report
NOK parts are automatically blocked
Documentation for internal and external customers
Track production faults
Improve overall quality by guaranteeing the quality of individual components