{"version":1,"type":"rich","provider_name":"Libsyn","provider_url":"https:\/\/www.libsyn.com","height":90,"width":600,"title":"Brother\u2019s blue technology revolution: How energy efficiency is transforming UK manufacturing economics","description":" The manufacturing landscape is shifting as energy costs and environmental responsibility become as important as speed and quality. Brother\u2019s Blue Technology leads this change, optimising machine design to minimise waste in time, resources, energy, and space. Peter Smith of Whitehouse Machine Tools, Brother\u2019s UK distributor, says it marks a paradigm shift in machine tool investment evaluation. MTDCNC spoke to Peter to find out more\u2026 Do your machine tools reduce energy consumption\u2014benefitting manufacturers\u2019 bottom line and the environment? \u201cThe Speedio series of machining centres from Brother certainly do. They use patented motor technology to capture and redeploy power, and they use less air, a dual benefit of Brother\u2019s Blue Technology approach.\u201d The Blue Technology Philosophy: Eliminating Manufacturing Waste Brother\u2019s Blue Technology eliminates waste throughout manufacturing, focusing on efficiency across the entire machine cycle. It emphasises the importance of how efficiently a machine produces, recognising modern competitiveness depends on this. The foundation of Blue Technology lies in Brother\u2019s \u2018low-mass, high acceleration\u2019 design philosophy, which Smith describes as fundamental to achieving superior efficiency. \u201cThe machines use Sanyo Denki drives\u2014the world\u2019s fastest reacting servo motors. They have a very special design with IPM interior permanent magnet technology that essentially harness energy like you would get from an F1 car. It\u2019s beautiful, really, the way that it works. So the acceleration and deceleration characteristics of the machine mean that the motors are creating lots of energy, but then they can harness that energy and redistribute it back into the machine.\u201d This energy regeneration technology marks a breakthrough in machine tool efficiency. During typical machining processes, the electrical energy produced during spindle and axis deceleration is usually converted into heat and lost. Brother\u2019s IPM (Interior Permanent Magnet) servo motors recover this energy and redirect it back into the machine system to establish a regenerative cycle Real-World Energy Performance: The 80% Reduction Achievement Smith\u2019s most compelling evidence for Blue Technology\u2019s effectiveness comes from extensive real-world field testing conducted with wireless energy and air monitoring equipment measuring actual consumption. \u201cUsing the wireless monitoring technology on a customers 40 taper 5 axes, we\u2019ve run the same program\/parameters on a Brother, 5-axes. Running the same parts on both machines, the Brother actually achieved almost 90% energy saving.\u201d This extraordinary 90% energy reduction translates into substantial financial benefits. Smith calculates the economic impact with precision: \u201cIf you take an average energy tariff in the UK, the Brother over the other machine doing the same job saves between \u00a35,500 to \u00a36,000 per shift per year. So, if we\u2019re operating a double shift, over a year, electricity savings will be \u00a311,000 to \u00a312,000. Over a five-year period, which is generally how people finance machines, manufacturers will save \u00a355,000+.\u201d \u201cThese savings compound across multiple machines. For manufacturers operating five machines on double shifts, the annual energy savings rise to \u00a3275,000 over a typical five-year financing period. In an era of volatile energy prices, these reductions provide both immediate cost benefits and long-term economic stability.\u201d Brother\u2019s own documentation supports this data, with official testing demonstrating 80% energy reductions in a variety of cutting applications compared to typical BT40 spindle machines. This performance stems from multiple on machine technological innovations working in collaboration, rather than any single efficiency improvement. The Four Pillars of Blue Technology Efficiency Brother\u2019s Blue Technology reduces waste in four areas, improving efficiency. The first focuses on eliminating time waste with high-acceleration \/ deceleration servo systems, optimised dynamics and rapid tool change times (0.7 seconds). Smith notes: \u201cIt\u2019s not about the rapid rate. It\u2019s about acceleration rates. Most machining centres operate around 0.6 to 0.8G axes acceleration, Brother Speedio\u2019 are much faster at up to 2.2G.\u201d These performance characteristics deliver healthy cycle time reductions, between 20% and 70% depending on the application, compared to 40 taper technologies. The second pillar targets resource waste through efficient coolant systems, LED lighting, and reduced compressed air consumption. Brother\u2019s mechanical tool change system exemplifies this approach, requiring minimal pneumatic assistance compared to traditional alternatives. \u201cThe whole tool change is mechanical using a linear cam mechanism. Air is only used briefly to clean the spindle taper. That\u2019s a huge saving when you look at air consumption,\u201d Smith notes. Energy waste elimination forms the third pillar, incorporating IPM servo motor technology, energy regeneration systems, and optimised control algorithms. The fourth pillar addresses space waste through compact machine designs that deliver equivalent or superior capability within significantly smaller footprints. Advanced Motor Technology: The Heart of Energy Efficiency Brother\u2019s energy efficiency is founded on IPM motor technology. Smith states: \u201cIPM interior permanent magnet servos respond quickly to rotation and stop, enabling efficient cutting with less power. Unlike normal induction motors, it starts instantly and efficiently.\u201d IPM motors incorporate permanent magnets embedded within the rotor, providing superior efficiency and responsiveness compared to induction alternatives. This design enables rapid acceleration and deceleration whilst minimising energy waste during speed transitions. The energy regeneration capability represents perhaps the most innovative aspect of Brother\u2019s motor technology. During deceleration cycles, the IPM motors function as generators, converting kinetic energy back into electrical energy. This recovered power is redistributed throughout the machine system, reducing overall grid consumption. The technology effectively transforms what was previously waste heat into useful energy, creating a regenerative cycle that compounds efficiency gains throughout extended operation periods. Brother\u2019s dedication to motor efficiency covers all machine axes. The Sanyo Denki servo drives for the linear axes offer quick response, ensuring energy efficiency benefits both positioning and cutting. Control System Integration Brother\u2019s D00 control system plays a crucial role in Blue Technology implementation, incorporating specific features designed to minimise energy waste during non-productive periods. Smith highlights the system\u2019s comprehensive approach: \u201cA variety of functions such as auto coolant off, auto machine lights off, and auto power-off are installed to ensure power saving.\u201d The control system\u2019s 1000-block look-ahead, sub-micron control capability enables optimised toolpath execution that minimises unnecessary acceleration and deceleration cycles. By analysing upcoming machining operations, the system can optimise spindle speeds and feed rates to maintain efficiency. The D00 control incorporates an energy monitoring application that enables real-time visualisation of power consumption, helping operators identify opportunities for further efficiency improvements. This transparency allows manufacturers to understand exactly how their machining strategies impact energy costs. Compressed Air Efficiency: The Often-Overlooked Savings While electrical energy consumption receives primary attention, compressed air efficiency represents another significant cost reduction opportunity. Smith emphasises this often-overlooked benefit: \u201cIt doesn\u2019t use a great deal of it, but the bit that it does use is obviously critical.\u201d Brother\u2019s mechanical tool change system exemplifies the compressed air efficiency approach. Unlike traditional tool changing systems that require significant air consumption for each operation, Brother\u2019s mechanical system requires only minimal air for chip clearing. The mechanical approach reduces air use during tool changes. While conventional systems need compressed air to stop the spindle quickly, Brother\u2019s system keeps it moving, eliminating this energy waste. For manufacturers operating multiple machines, compressed air savings can represent thousands of pounds annually. The efficiency gains also reduce compressor sizing requirements for new installations, providing capital cost savings beyond operational benefits. The Hidden Economics The total cost of ownership analysis shows advantages of Blue Technology adoption. Beyond energy savings, manufacturers see reduced maintenance. The mechanical tool change system wears less than pneumatic options, and IPM motors\u2019 efficiency decreases heat and bearing stress. Factory costs compound the economic benefits of Brother\u2019s compact designs. Smith calculates that Brother machines typically require 25 to 30% less floor space than equivalent BT40 systems. In high-value manufacturing, this can save thousands. The reliability benefits further enhance the total cost of ownership (TCO). \u201cBrother machines are built for lights-out three-shift running. So our advice is run them flat out.\u201d Environmental Responsibility Brother\u2019s Blue Technology addresses rising corporate environmental standards by reducing CO2, supporting sustainability goals, and offering cost savings. Smith recognises the growing importance of environmental performance: \u201cCompanies\u2019 efforts to promote energy saving bring a variety of values for their business operations. Amid global calls for carbon neutrality, promoting energy saving and contributing to decarbonisation will lead to an increase in corporate value.\u201d For manufacturers pursuing environmental certifications or carbon trading schemes, the measurable efficiency improvements provided by Blue Technology offer valuable documentation. Overcoming Traditional Thinking Despite the compelling economic and environmental benefits, Smith acknowledges market perception of BBT30 Blue Technology, due to historical misconceptions and early adoption of 40 taper technologies, needs to be more open minded. \u201cEngineers typically operate on personal experience or that or their peers and the UK market was an early adopter of 40 taper technology from manufacturers like Bridgeport & Cincinnati. Brother BBT30 Blue Technology has advanced so far in the last decade in efficiency and cutting capability, 40 taper users who have become uncompetitive now have the opportunity to regain a competitive edge with Brother\u201d Smith continues: \u201cWe get too carried away with brand loyalty. Not one machine tool manufacturer has all the answers, furthermore buyers become fixated on a deal rather than TCO. WMT CNC & Brother are developing a method of predicting TCO for machine investments so buyers can take a long-term investment decision at the point of purchase. The journey to market transformation requires manufacturers to assess machine tool investments through thorough economic analysis rather than relying on past preferences. Smith\u2019s approach stresses empirical testing: \u201cSupply us with your ISO programme. We\u2019ll run it, and we\u2019ll give you our honest opinion about whether a BBT30 taper Brother could improve the ROI.\u201d   ","author_name":"MTD Audiobook","author_url":"https:\/\/mtdcnc.com\/magazine","html":"