Control technology and cabinet design for a compact high-tech grinding machine
The Multigrind Radical from Adelbert Haas combines highly precise machine building, in-depth process expertise, and intelligent proprietary software in a compact, fully automated high-tech grinding machine designed for highly efficient mass production. As part of the machine’s ongoing development, Adelbert Haas has redesigned the control technology and cabinet architecture, making a conscious decision to choose PC-based control and cabinet design from Beckhoff. The goal was to further improve the performance of the Multigrind Radical, reduce system complexity, and create an open, future-proof automation platform for the company’s proprietary software architecture.
Adelbert Haas GmbH specializes in the development and production of highly precise universal grinding machines. The company is known for its unique combination of machine building expertise, grinding technology, and proprietary software development. Marie-Sophie Maier from Adelbert Haas sees this as a key differentiator: “Our goal is to establish a connection between machine building, process expertise, software, and full automation to create a single, intelligent system. Our proprietary software enables users to plan processes precisely in advance and then machine complex workpieces with micrometer precision.”
The machines in the Multigrind series are used in demanding industries such as medical technology, aerospace, cutting tool manufacturing, and professional toolmaking. Precision, process reliability, flexibility, and productivity are all equally important in these markets. The Multigrind Radical has been developed specifically to meet these requirements.
Multigrind Radical further developed for improved performance
Two years after the product launch, Adelbert Haas began further developing the control technology and control cabinet architecture. The goal was to systematically adapt the existing machine platform to deliver higher performance while making it more open and future-proof. Series production of the upgraded model began in the middle of last year.
Gerhard Schnee, Head of Electrical Engineering Development at Adelbert Haas, describes the decision: “We defined our requirements for the future control architecture very clearly and then made a conscious decision to choose Beckhoff. The deciding factors for us were the open, PC-based control platform, the high level of flexible performance, and the ability to ensure precise, synchronized, and transparent availability of real-time data from the machine. This aligns very well with our proprietary software architecture and our goal of creating an intelligent combination of machine building, grinding process, and software.”
The decision to adopt Beckhoff technology was therefore not simply a matter of replacing individual components, but rather a strategic step in the roadmap for ongoing development of the Multigrind Radical. Adelbert Haas was specifically looking for a solution that would expand the company's expertise in machinery and software rather than limit it. With PC-based control, Adelbert Haas is using an open control architecture that provides additional flexibility for future functions, diagnostic capabilities, and IT integration.
The Multigrind Radical has been specially designed for highly efficient mass production. According to Martin Trittler, Technology Developer at Adelbert Haas, its strength lies in the combination of productivity, compact design, and ease of use: “With the Multigrind Radical, we can offer users a highly productive and compact grinding machine that is also easy to use. It enables quick product changeovers, maximum performance, and a high degree of flexibility in production. It is particularly important to us that the machine is ready for use without the need for lengthy training and offers a fully automated solution for demanding tool grinding processes.”
PC-based control as a platform for advanced software expertise
At Adelbert Haas, control technology is not an end in itself. It is part of a comprehensive system that combines precision mechanics, grinding technology, and proprietary software intelligence. For the upgraded Multigrind Radical, Adelbert Haas therefore specifically chose an automation platform that supports the company’s own machine and software architecture and allows for long-term further development.
That's why the company decided to use PC-based control technology from Beckhoff. Key factors included the open system architecture, the integration of PLC, CNC, and HMI on a single CPU, and the ability to make machine and process data available with precision and in sync with real-time control processes. As a result, it is possible to achieve shorter cycle times, reduce the number of hardware interfaces, simplify the cabling requirements, and improve diagnostic capabilities. At the same time, the control technology can be designed to have a more compact set-up and better meet IT requirements.
The key factors in favor of using TwinCAT 3 CNC software were, in particular, its high level of CNC functionality, its seamless integration into the TwinCAT system, and the many years of market experience offered by Beckhoff in the field of CNC automation. From the perspective of Adelbert Haas, however, the most important factor was that the solution aligns with the company’s own development philosophy: open, powerful, and flexible enough to integrate and expand the software architecture.
The control system is based on a CX2043 Embedded PC running TwinCAT 3, numerous EtherCAT and TwinSAFE Terminals, and the AX8000 multi-axis servo system. This system controls both third-party linear axes and Beckhoff AM8043 servomotors for the Z-axis and the tool changer.
Martin Trittler explains: “We selected Beckhoff because the platform fits our approach to building machines. Our strength lies in the combination of grinding technology, machine building, and our proprietary software. This means we need a control system that is open, powerful, and capable of long-term development. TwinCAT 3 offers us exactly this level of flexibility – from the flexible distribution of CNC and PLC tasks and multi-core support, as well as the ability to utilize real-time data with precision for our higher-level software.”
A key consideration is integration into the company’s own software architecture. Martin Trittler continues: “The kinematic interpolation for our grinding machines is calculated by our higher-level proprietary software. Therefore we need a control system that provides values such as position feedback, tracking error, current, force, and torque in a simple, precise, and synchronized way. That’s exactly why we opted for PC-based control from Beckhoff.” His conclusion: “The Beckhoff technology complements our own expertise in machinery and software very well. It gives us the openness and performance we need for an ongoing evolution of the Multigrind Radical.”
New control cabinet design for a compact grinding machine
The change in the control system for the Multigrind Radical also required design modifications. Since the machine’s external dimensions had already been determined, maintaining the same form factor was a key requirement. The Radical does not have a traditional control cabinet. Instead, the control system is distributed across three mounting plates, which are integrated directly into the machine housing during installation.
For Adelbert Haas, this meant it was crucial for the new control architecture to integrate seamlessly into the compact machine design. Marie-Sophie Maier explains: “It was clear to us from the very beginning that the new control architecture had to be compatible with the design of the Multigrind Radical. We made a conscious decision to choose Beckhoff because it offers both control technology and control cabinet design from a single source, and the components used are very familiar. This reduces the number of interfaces and makes implementation much easier.”
Marie-Sophie Maier adds: “The division of responsibilities was clear: Adelbert Haas defined the requirements related to machinery, processes, operation, and service. Beckhoff translated these requirements into a suitable electrical engineering concept. It was precisely this combination that led us to choose Beckhoff as our partner.”
From the perspective of Adelbert Haas, there is a particular advantage in the reduction of interfaces and the seamless interaction between control technology and control cabinet design. “Having everything supplied from a single source makes coordination much easier,” says Marie-Sophie Maier. “At the same time, we were able to focus on our core competencies: machine design, the grinding process, software, and our customers’ competitiveness.”
Multigrind machine with a carefully chosen foundation
With its new control technology and control architecture, Adelbert Haas has developed the Multigrind Radical in a targeted way. The machine retains its compact design but gains in performance, openness, and diagnostic capabilities. At the same time, this creates a foundation that will more effectively support future requirements for software, data availability, IT integration, and cloud-based functionalities.
The decision to select Beckhoff aligns with the development roadmap of Adelbert Haas. The open PC-based control architecture complements the company’s own expertise in machinery, processes, and software, and provides additional flexibility for further developing the Multigrind Radical. The technological roadmap remains clear: Adelbert Haas defines the requirements, develops the grinding solution, and shapes the future of the machine, while Beckhoff provides the automation and control cabinet platform specially selected for this purpose.