Flow Waterjet Delivers Faster, More Accurate Shape Cutting Solutions with Omron Automation

The Challenge
Flow Waterjet's primary challenge in enhancing their shape cutting machines was meeting the rising demand for both precision and flexibility. Customers required greater accuracy and the capability to cut a diverse range of materials. They aimed to provide a high-speed option that allowed customers to cut soft goods with water-only at a faster rate – the Mach 200s.

Another challenge was accommodating customers who required a waterjet in a clean environment, such as precision machine shops or educational facilities. To meet this demand, Flow Waterjet needed to develop a fully enclosed version of their machine, known as the EchoJet.  

Other challenges Flow Waterjet encountered was the time-consuming and complex commissioning process. They aimed to reduce the commissioning time of their machines to enable faster deployment and increased productivity. Streamlining the commissioning process was crucial to meet the evolving demands of their customers, maintain a competitive edge in the market and shorten the time of ROI.

Additionally, Flow Waterjet recognized the significance of enhancing the safety features of their machines. They understood the importance of providing a secure operating environment for operators and ensuring compliance with updated functional safety standards. Adding advanced safety features to their machines was a priority to protect both the operators and the machines themselves.

Solution
To address the challenges, the company partnered with Omron Automation to expand their technology. With OMRON’s PMAC (Programmable Multi-Axis Controller) platform at the core of the solution, the servo drives, motors and advanced safety system were seamlessly integrated. This solution seamlessly integrated into Flow Waterjet's machines, enabling precise control, efficient operation, and enhanced performance.

By incorporating OMRON’s advanced motion control technology, Flow Waterjet was able to achieve unprecedented precision and efficiency in their machines. The PMAC controller provided state-of-the-art motion control capability, ensuring accurate and smooth movements. Advanced servo drive tuning provided positional accuracy and motion stability over the broadest spectrum of cutting speeds. The new architecture offers reliable and precise control over the machine's movements, further enhancing the overall performance.

In addition to motion control, OMRON's solution included a safety controller. These components ensured the safety of the operators and the machine itself, meeting the stringent requirements of the industry. The safety controller monitored and controlled the machine's operation, minimizing potential hazards.

Furthermore, OMRON’s engineering expertise played a crucial role in the successful integration of their solution into Flow Waterjet's machines. The OMRON team worked closely with Flow Waterjet to understand their specific requirements and challenges, providing tailored solutions and support throughout the process. This collaboration resulted in a seamless integration of OMRON’s technologies into Flow Waterjet's machines, delivering the desired precision, efficiency, and flexibility.

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The Benefits
One of the major achievements was the significant increase in accuracy. By leveraging OMRON's advanced motion control technology and servo solution, Flow Waterjet achieved precise control over the machine's movements. Flow was able to more than double cutting speeds while maintaining or improving positional accuracy. The new system architecture resulted in improved performance and greater customer satisfaction. The PMAC architecture accommodates multiple machine configurations. The flexibility of the PMAC allows customization for special user needs beyond the standard products.

Another key benefit was the reduced commissioning time. With the integration of OMRON technologies, the commissioning time was greatly reduced, saving valuable resources and allowing the machines to be put into production faster. This accelerated deployment enabled customers to start utilizing the machines more quickly and efficiently, boosting productivity and decreasing time-to-market.

Furthermore, OMRON added a significant layer of safety to Flow Waterjet's machines. The safety controller monitored and controlled the machine's operation, minimizing potential hazards and ensuring the well-being of the operators. These benefits collectively contributed to the overall success and customer satisfaction of Flow Waterjet's enhanced shape cutting machines.

Future Opportunities
Building on their successful collaboration, Flow Waterjet is exploring future opportunities to further enhance their machines. They have plans to launch another new system, expanding their product offerings. Additionally, they are working on the development of a Rotary Indexer (6th-axis) option and new Ultra-High Pressure pump models. These future opportunities will provide customers with even more advanced capabilities, allowing them to tackle a wider range of cutting applications. By continuously innovating and pushing the boundaries of shape cutting technology, Flow Waterjet will undoubtedly maintain their position as industry leaders.

Conclusion
The collaboration between Flow Waterjet and Omron Automation resulted in a transformative enhancement of shape cutting machines. By integrating Omron Automation's cutting-edge solution, Flow Waterjet overcame their challenges and achieved unprecedented precision and efficiency. The machines offered increased flexibility, faster cutting speeds, reduced commissioning costs and added safety. These advancements not only positioned Flow Waterjet competitively in the market but also impressed customers with innovative solutions. With future opportunities on the horizon, Flow Waterjet is poised to continue evolving the industry and setting new standards for shape cutting machines.