Heller harnesses AI to raise productivity

HF 3500 five-axis machining centres will be on the Heller stand at EMO linked to a Robot Cell Professional robotic system for automated workpiece and pallet handling

Artificial intelligence (AI) at machining centre manufacturer Heller is already a reality, focused on the clear goal of raising the productivity of the company’s customers. Working in collaboration with trusted partners, Heller has accumulated the expertise needed to integrate digital solutions with AI elements into machining cells and is already applying the technology across three platforms, intended to support machine operators, production planners and service personnel. The way in which these developments are delivering added value will be presented at the EMO Hannover 2025 exhibition, taking place from 22-26 September (Hall 12, Stand C70).

Visitors to the stand will have the chance to witness live demonstrations on two Heller five-axis machining centres, the HF 3500 and F 5000. Both models will be equipped with new automation solutions for workpiece and tool handling respectively. The manufacturing cells enable automated production of complex components, especially in the aerospace, hydraulics and pneumatics, and power generation sectors.

Several years ago, the company formed a cross-departmental team of specialists dedicated to digitalisation and AI, with the remits to make machine operation more efficient and to enable predictive maintenance and production planning. Dr Thorsten Schmidt, Heller’s CEO and an enthusiastic supporter and driver of this initiative, said: “We are concentrating on these three key areas, as AI delivers real advantages. At EMO, we will present practical applications and the concepts behind them. The way in which operators are digitally supported throughout the entire process chain will be demonstrated.”

Pictured left: the HF 3500 has twin-bearing table kinematics as standard

Operators have access to AI-powered software and system functionalities, including SETUP-Assist, PRODUCTION-Assist and, to ensure component accuracy, the newly developed QUALITY-Assist. Additionally, by measuring temperature increases in the spindle, even the smallest growth can be calculated and compensated for, allowing the machine to maintain maximum precision and productivity without any specific operator intervention.

A new feature to be unveiled at EMO provides customers with an intelligent chat function, ‘ASK-me’. This tool, integrated into the control interface, provides operators with a ChatGPT-like assistant. Users are able to enter questions in plain language, after which the AI function quickly delivers clear, straightforward answers. The AI assistant uses the collective expertise of Heller and its users to provide answers and support relating to machine operation, including setup and maintenance, and helps to interpret warning and error messages.

AI-powered analysis tools
Heller will also showcase AI-powered analysis tools, which offer valuable benefits for maintaining the productivity and high precision of modern machining centres. To achieve this, the machine manufacturer uses data collected as part of its Industry 4.0 strategy. The information can be visualised by production planners and analysts via the shopfloor system Heller Services Interface in the form of text, tables or diagrams. It ensures transparency in production, maintenance and service throughout the lifecycle of the machine. For instance, machine downtime can be identified using a generatively produced chart, whilst AI-supported analysis of production data helps to reveal potential for boosting output.

Heller service engineers will show how the combination of data acquisition and intelligent analysis provides key insights for preventative maintenance. Returning to the previous example of the spindle: run times, load and overload phases, and spindle speed values are routinely recorded in addition to temperature trends. Based on this, it is possible to monitor the spindle’s condition and to prevent unplanned machine downtime from wear-related failure. The same principle applies to other components, such as axis drives and tools.

Pictured right: the Heller F 5000 five-axis machining centre, equipped with a rack-type tool magazine, will be on display at EMO 2025

Due to its table kinematics featuring counter bearings as standard, as well as its high dynamics and short non-productive times, the PRO version of the HF 3500 on display will be a main attraction. It has a Z-axis driven on both sides, high acceleration of 10m/s², axis speeds of 90m/min and very short chip-to-chip times. Heller’s high-performance spindle, featuring the proven zero-spindle quick-change system, ensures maximum productivity. Its combination of high torque and speed makes it ideal for a wide variety of applications. The machine will be linked on the stand to a Robot Cell Professional, a standardised robotic automation solution for automated workpiece and pallet handling.

The F 5000 with head kinematics, which is used for machining heavier components, is distinguished by its HSK-A 63 motor spindle. Due to the modular design, it may be optimally configured for a diverse range of small to medium batch size applications. Thanks to its tilt head, the machine is especially flexible and well-suited to the machining of undercuts and recesses, which is applicable in particular to aerospace industry applications.

Notable also will be a demonstration of how quickly and easily tools can be changed in batches using a newly developed rack-type tool magazine connected to the F 5000. With this type of automated tool changeover, several worn tools are removed from the machine together in a single cassette and replaced with new tools that have been preset and placed in a mobile rack. Owing to their slimline design, the new rack magazines offer an optimised footprint and can store up to 340 HSK-A 100 tools or approximately 490 HSK-A 63 tools. A version with 260 pockets will be on display at the trade fair.