High-Precision Grinding Machine Control with Flexible HMI Solutions

Application Area: Industrial Automation / Grinding Technology
Industry Sector: Machine Tool Manufacturing

WMT Leipzig GmbH, a manufacturer specializing in cylindrical and centerless grinding machines, required a specialized control interface for its new machine developments. Traditional human-machine interface (HMI) solutions available on the market are predominantly optimized for turning and milling operations. These standard systems offered limited support for the specific complexities of centerless grinding and lacked the necessary depth of access to NCK data required to optimize machine performance. The company sought a solution that would provide maximum operational freedom and ergonomic efficiency within a strict ten-month development window for the CIMT 2023 trade show in Beijing.

Open Software Architecture for Process Optimization
The technical solution centered on the AP 524 control panel and a software-first framework provided by KEBA. The selection of this platform was driven by its hardware-independent nature and high level of openness toward third-party technologies. Utilizing JavaFX support, WMT Leipzig integrated existing libraries and interfaces, which accelerated the development cycle and ensured long-term modularity.

This open architecture allows the HMI to function as a tool for quality assurance. For example, the system can calculate the probability of polygon formation during the grinding process directly within the interface. By processing this data in real-time, operators can implement immediate process optimizations to maintain high-precision standards and reduce scrap rates.

Tactile Feedback and Multifunctional Input Devices
To improve safety and reduce physical complexity, the deployment utilized force feedback technology. This system replaces traditional physical hardware buttons for safety-critical functions like start and stop with tactile feedback delivered through the glass surface. This "operation under glass" philosophy reduces mechanical wear and increases the clarity of the user interface.

The integration of the KeWheel multifunctional input device further streamlined the hardware requirements. This single component functions as a feed override, spindle override, or electronic handwheel depending on the operational context defined by the HMI or PLC. This flexibility is particularly beneficial during machine setup, where the feed can be reduced to 0% to allow for the safe approach of critical machine movements, thereby improving both ergonomics and operational safety.




Impact on Productivity and Machine Management
The shift toward a software-centric machine design has resulted in a more transparent production process and a direct impact on productivity. By having direct access to control data and flexible visualization, the operator's ability to manage complex grinding tasks is significantly enhanced.

Following the successful implementation across several machine types, the partnership is currently developing an HMI-based tool management system. This ongoing development aims to further simplify machine operation and unlock additional efficiency potentials in tool tracking and maintenance scheduling.




Additional Context
The AP 524 hardware utilized in this application features a high-resolution multi-touch display designed for harsh industrial environments, offering IP65 protection. Unlike closed proprietary systems that restrict data flow between the HMI and the numerical control, this solution provides an open API for deep NCK integration. In competitive benchmarking, this level of transparency allows for the implementation of custom algorithms—such as the polygon formation calculations used by WMT Leipzig—without requiring external processing hardware, a capability often limited in standard CNC control packages.

Edited by Romila DSilva, Induportals editor – adapted by AI.