Together with strong partners, HELLER has acquired the necessary know-how to gradually but purposefully integrate digital solutions with AI elements into mechanical engineering. The machine manufacturer is already utilizing them based on three platforms that make work easier for machine operators, production planners, and service staff. How these developments are already generating real value creation is demonstrated by the company's experts at this year's EMO. In addition, the state-of-the-art five-axis machining centers HF 3500 and F 5000 can be experienced in action at the trade fair. They are equipped with newly developed automation solutions for workpiece and tool handling, which can also be connected to other HELLER machining centers. Such manufacturing cells can produce a wide variety of highly complex components for the aerospace industry as well as for many other sectors, such as general mechanical engineering, fluid technology, and energy technology – if needed, without operators and over entire weekend shifts. The results – two world-renowned "monumental structures" – are equally impressive. A visit is worthwhile.
Not only in everyday life are digitalization and artificial intelligence becoming increasingly important. These modern tools can also be utilized for industrial applications. As one of the leading manufacturers of CNC machine tools and manufacturing systems, HELLER recognized this early on and brought together a group of specialists years ago who focus on digitalization and AI across departments, collaborating with external partner companies to generate solutions – from more efficient machine operation to predictive maintenance and production planning.
Dr. Thorsten Schmidt, CEO at HELLER, supports and promotes this initiative. He makes it clear: "We have with machine operation, maintenance/service and
Production planning: three topics in focus that can benefit from AI, leading to increased productivity for our customers. At EMO 2025, the company will provide insights into concrete applications and the underlying concepts.
Process-oriented assistance – digitally supported
Two state-of-the-art five-axis machining centers – an HF 3500 and an F 5000 – will not only be permanently showcased in operation. HELLER will also demonstrate how operators are digitally supported throughout the entire process chain on these machines. During setup with the "SETUP Assist," in the manufacturing process with the "PRODUCTION Assist," and in ensuring component accuracy with the newly developed "QUALITY Assist." For example, measured temperature increases in the spindle can be used to calculate and compensate for even the smallest length growth.
Data-driven & intelligent – AI in the process and in analysis
Starting from EMO 2025, customers will have access to the intelligent chat function "ASK-me." Integrated into the machine control interface, this tool provides operators with a functionality similar to ChatGPT. This means that users can input questions in clear language, and the AI function will quickly provide answers in the same clear language. The AI assistant utilizes the accumulated HELLER and user knowledge in its responses and supports machine handling (operation, setup, maintenance) as well as the assessment of warning and error messages based on the live status of the machine. AI-supported analytical tools, which HELLER will present at EMO, are also extremely helpful for the productive and highly precise operation of modern machining centers. The Nürtingen machine manufacturer uses data as a basis that has already been gathered as part of its Industry 4.0 strategy.
Data from the machines is captured and can be visualized for the production planner/analyst in the shop floor system HELLER Services Interface as text, tables, or diagrams. This ensures transparency in manufacturing, maintenance, and servicing processes throughout the entire lifecycle of the machine. For example, the question of hidden downtime of the system can be addressed through a generative...
The generated chart visualization answers questions, and the AI-supported analysis of production data reveals potential for optimization to increase production.
The combination of data collection and intelligent analysis plays an important role in preventive maintenance, as demonstrated and explained by the service experts from HELLER at the trade fair. To continue with the previous example of the HELLER spindle: In addition to temperature developments, operating times, load or overload phases, and speed values of the spindle are also documented as standard. Based on this data, the condition of the spindle can be monitored, making it possible to prevent unplanned machine downtime due to wear-related spindle failure. This approach works similarly for other components such as axes or tools.
Simultaneous five-axis machining with different characteristics
In addition to the digital highlights, HELLER will also showcase its comprehensive offerings at EMO 2025.
Mechanical engineering expertise in the form of two five-axis machining centers. The HF 3500 is characterized by a table kinematics with standard counter bearings as well as high dynamics and short non-productive times. The machine displayed at the trade fair also features a double-driven Z-axis in the PRO configuration and is equipped with all the features necessary for perfect simultaneous machining.
The high acceleration values of 10 m/s², axis speeds of 90 m/min, and the extremely short chip-to-chip time are also advantageous. Additionally, maximum productivity is ensured by the powerful spindle developed in-house by HELLER, featuring a proven zero spindle system. Its combination of high torque and high speed makes it ideal for universal applications.
For the machining of heavier components, the F 5000 with head kinematics is used. It is characterized by numerous features and key components, such as a motor spindle with HSK-A 63 interface. Due to its modular design, the F 5000 can be optimally configured for a wide range of applications, always ensuring the highest precision and performance in the production of small to medium batch sizes. Equipped with a fork head variant, this machine is particularly flexible and, for example, is excellently suited for undercuts and recesses.
Latest automation variants for workpiece and tool handling
For companies that want to manufacture constantly changing workpieces with a manufacturing cell, another innovation is interesting - the 'Robot Cell Professional', short RP4. It will also be showcased at EMO 2025. Docked to the HF 3500 as an example, it can also be used in combination with the HF 5500 and the four-axis series H. As standardized robot automation in the program, it is extremely flexible in its application area thanks to its multi-batch capability. It can load and unload the machining center in any order with various components as well as with pallets including clamping devices.
An integrated digital twin facilitates the main time-parallel setup of the RP4. With appropriate workpiece storage, it is possible to realize unmanned shifts and even an autonomous weekend operation.
Equally interesting: HELLER shows at the trade fair stand how easy and quick it is to set up tools in batches with a newly developed tool rack magazine connected to the five-axis machining center F 5000, including 'Mobile Rack'. In this type of tool automation, several worn tools are always removed together (in a cassette) from the machine and replaced with new ones that were previously prepared in the setting room and placed in the Mobile Rack.
The new rack magazines, optimized in terms of footprint due to their slim design, can store up to 340 HSK-A 100 or around 490 HSK-A 63 tools. The variant with 260 slots will be exhibited at the fair. The optional Mobile Racks can be combined with all sizes and can also be equipped for fully automated use with their own drive. This makes it possible to fully automate the transport of tools to and from the machining center. This relieves the operator and saves valuable working time.
HELLER at EMO 2025 - in Hall 12, Stand C 70
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