Smart automation for advanced metalworking
The metalworking industry is evolving rapidly, driven by innovations such as laser cutting, adaptive manufacturing and deeper integration with CAD/CAM systems. To remain competitive, machine builders need automation solutions that maximize precision, flexibility and efficiency while keeping pace with changing requirements.
B&R's scalable automation platform is designed to meet these challenges. With mapp CNC, machine builders get an open and highly customizable CNC solution that seamlessly integrates with CAD/CAM workflows for increased adaptability and efficiency. Our high-speed motion control, intelligent robotics and intuitive HMIs ensure optimal performance in applications such as milling, grinding, cutting and forming.
By combining advanced CNC technology with Industry 4.0 connectivity, B&R helps machine builders increase productivity, reduce waste and future-proof their operations. Discover how our innovative automation solutions can take your metalworking business to the next level.
The growing importance of software
With increasing digitalization and automation, software solutions must be seamlessly integrated into existing production systems, which is often complex. Connected production also requires a high level of IT security to protect production data and prevent cyberattacks. Software must be flexible enough to respond quickly to changes in production or market demand, especially when producing small batches or customized products.
High production costs & inefficiencies
Rising raw material and energy costs, as well as machine downtime and long set-up times, have a significant impact on profitability. Inefficient workflows and frequent manual adjustments slow down production and increase waste. Machine builders need automation, predictive maintenance and optimized CNC integration to streamline processes, reduce costs and increase productivity. However, change can be costly and requires careful planning to ensure profitability.
Simulation & offline programming
While technology can help optimize production processes and detect errors before they occur, it also presents a complex challenge. Accurate simulation of machine movements and processes requires precise models and large amounts of data, which are not always easy to create or integrate. In addition, the programmed sequences must be seamlessly transferred to real production, which can cause problems if the simulation is faulty. Even offline programming, where programs are created and tested outside the production environment, assumes that the programs can run in the field without adjustments or unexpected results.
Sustainability & energy efficiency
In the face of increasing environmental and climate impact, metalworking companies need to make their production processes more sustainable. This includes reducing energy consumption through more efficient machinery and the use of renewable energy. Improving the recyclability of materials is also becoming increasingly important to conserve resources and minimize waste. Companies need to use more environmentally friendly materials and reduce CO2 emissions to meet the increasing demands of legislators, consumers and investors.
Challenges of integration & digitization
Many machine builders face the challenge of integrating CNC machines, CAD/CAM systems, and automation into a seamless digital workflow. Legacy systems are often not networked, making it difficult to implement Industry 4.0 solutions such as real-time monitoring and predictive maintenance. It is difficult for small and midsize companies to invest in the infrastructure and expertise required for full digitalization.
Technological progress & market competition
New technologies such as laser cutting, additive manufacturing and intelligent robotics are transforming metalworking, bringing greater efficiency and precision. However, implementing these advances requires significant investment and expertise. Companies that fail to modernize risk falling behind their competitors, who are using automation, AI-driven process optimization and agile manufacturing to increase productivity and meet evolving market demands. Keeping pace with innovation is critical to long-term success.
Customized automation solutions for metalworking excellence
Human-Machine Interface 4.0
B&R's customizable operator panels make the control of complex machine tools more efficient and user-friendly. The panels and controls can be customized to meet specific requirements, emphasizing the uniqueness of the machine and strengthening the brand. B&R's web-based HMI software makes it easy to create modern user interfaces - even without extensive web development knowledge. The advantage: a customized, intuitive user interface that sets machines apart and increases process efficiency.
Scalable hardware & software solutions
B&R offers machine manufacturers a scalable platform that is tailored exactly to the requirements of their machines. From low-cost to high-performance solutions, the versatile portfolio of industrial PCs, controllers and HMI devices is perfectly matched. The drive technology is optimally adapted to the respective application and software-independent development enables faster time to market. The advantage: higher efficiency, lower costs and an open solution that meets all machine requirements.
Open & easy software development
mapp Technology enables rapid programming and immediate testing of machine tools. Integrated simulation and diagnostics speed up development and commissioning. The B&R CNC system combines the controller and CNC on a single processor, ensuring highly synchronized communication. The openness integrated into the system through the interpreter offers a high degree of flexibility for the future. This can also be used for an easy transition from older machines. mapp Technology provides a powerful tool for simulation, programming and commissioning – ideal for flexible and efficient machines.
Free choice of CNC syntax
B&R systems offer machine manufacturers maximum freedom when selecting the CNC syntax. From standardized DIN 66025 G-code to user-specific commands, the possibilities for implementing a customized solution for machine tools are virtually unlimited. The standardized DIN 66025 G-code allows for easy integration of CAD/CAM systems, while the free choice of syntax also allows for the use of existing third-party programs.
Comprehensive security technology
B&R's integrated safety technology enables modular machine and system concepts where standard and safety machine modules are connected to a common network via POWERLINK. With the PLCopen safety library for press applications, B&R offers a comprehensive implementation of safety-related functions for mechanical, electrical and hydraulic presses. B&R's safety technology complies with all relevant standards, including IEC 61508, IEC 62061 and ISO 13849. Advantages include greater machine modularity, a single safety application for a variety of options and simplified machine mechanics with a smaller footprint.
Integrated robotics
B&R makes it possible to seamlessly integrate robots into the machine control system. Whether it's a press brake, transfer machine or machining center, the machine and robot share the same processor and memory, allowing highly synchronous communication with a jitter of less than 1 µs. The shared DC bus for the drives ensures maximum energy efficiency. Machine builders also benefit from web-based diagnostics and remote maintenance, increasing productivity. Customers benefit from maximum productivity and energy efficiency by synchronizing robots and machine tools.
OPC UA for integrated networks
Vertical and horizontal networking of production is a key factor for Industry 4.0. With OPC UA, machine tools can be seamlessly integrated into production management systems such as SCADA, MES and ERP. B&R has deeply integrated OPC UA into the automation system so that every B&R controller can act as an OPC UA server and client. In addition, new PLCopen function blocks for OPC UA are constantly being developed. The result is seamless networking for efficient and modern production.
References & Success Stories
Perfect fiber laser cutting and bending
A unique machine from Amada that combines cutting, bending, punching and forming. Thanks to close cooperation with B&R and the use of Automation Studio, a highly precise and responsive machine was developed that automatically produces complex products in the shortest possible time. With this development, Amada was able to create an innovative solution that meets the highest standards of quality and efficiency in just two years.
Modularity and efficiency
The Albiez ET 15 32 from Bjm Dubus Maschinenbau (BDM) in Germany enables fully automatic 6-sided machining of profiles, including special functions such as tapping without a compensation chuck. The automatic tool changer and the machine's high level of hardware and software modularity allow flexible implementation of customer requirements. The reliable POWERLINK and OpenSafety industrial networks guarantee maximum safety and flexibility and the control technology is designed for efficiency and reliability.
Laser cutting and welding machine for all metals
Elettrosystem's TWIMP is a state-of-the-art machine that can both cut and weld special metals such as TWIP, an austenitic steel with induced plasticity. Thanks to the perfect integration and synchronization of all moving parts through the unique Automation Studio programming environment, the machine is capable of complex 3D movements with a repeatability of less than a tenth of a millimeter.
Maximum production precision and efficiency
Trumpf uses B&R control technology for two high-precision machines: the TruLaser 1030 and the TruBend 7036. By integrating B&R real-time operating systems and user-friendly HMI designs, Trumpf offers a flexible, efficient and productivity-enhancing solution for laser and bending technologies. With worldwide support and advanced diagnostic capabilities, B&R ensures a seamless connection between control and operation.
World-leading waterjet technology
Flow International relies on B&R technology to keep their machines at the highest level of performance and ease of use. The Flow Mach 4C uses B&R Automation Studio and real-time operating systems for precise control and high productivity. B&R's servo motion technology and safety solutions are used to meet the highest performance and safety requirements. By working closely with B&R, Flow is able to develop innovative products that provide customers with excellent support and a quick return on investment.
New levels of flexibility and precision
Ursviken Technology AB offers high quality presses with flexible solutions for individual requirements. The machines range from 100 to 10,000 tons and offer numerous options, including a six-stage backgauge and crowning table. With B&R's control solution, customers benefit from reliable and flexible automation that enables precise control and programmable adjustments. The excellent support and high quality of the machines ensure efficient production and maximum performance.
A new level of precision and performance
Fermat grinding machines equipped with the B&R Power Panel 500 offer a user-friendly and safe control system that is specifically tailored to the customer's needs. With open CNC technologies and graphically supported cycles, grinding processes can be efficiently controlled without programming knowledge. The machines offer maximum flexibility and reliability with minimum maintenance. The integration of external linear encoders and the ACOPOS drive system maximizes precision and significantly increases performance.
The most flexible sheet metal machines for global solutions
With more than 90 years of experience in sheet metal processing, Geka offers modern solutions for cutting, drilling and punching for the steel industry. The partnership with B&R provides Geka with a reliable automation platform that enables precise control and maximum flexibility in new automated production lines and drilling stations. Close cooperation with B&R engineers was essential to provide the best tools for the customer's requirements.
Maximum flexibility and efficiency
Coproget offers flexible, modular special machines for cold metal forming that use B&R technology for fast configuration and easy tool change. The decentralized ACOPOS motor drives guarantee precise control, while the Diagnostic Manager allows for easy maintenance and fast error detection. B&R ensures maximum flexibility, efficiency and machine availability.
Optimized automation with B&R
KSK is known for its innovative hardfacing and welding machines, which are highly valued in the automotive, glass and machine manufacturing industries. Thanks to its long-standing partnership with B&R, KSK is able to equip its machines with the latest automation technology. With B&R controllers and POWERLINK for communication, the PTA machines operate in six axes and offer the highest precision and reliability.
Additional contact options for B&R: Local value provider
Find a partner near you
Take advantage of our global network for end customers.
In addition to more than 200 B&R offices in over 70 countries around the world, we have a global network of partners. B&R Value Providers work seamlessly with B&R to bring our products and services to your door. They combine in-depth knowledge of B&R technology with a deep understanding of your local market.