Compact pressing technology with full performance

Abacus Maschinenbau is once again relying on linear technology and measuring systems from Hiwin for its new Premo 300 Nova.

Amid cost pressures, uncertainty, and rising demands, the special-purpose machinery sector requires solutions that are flexible, cost-effective, and technically sound all at once.
  
Abacus Maschinenbau GmbH rises to these challenges and addresses them with well-thought-out, practical machine designs—most recently with the Premo 300 Nova, a new milestone in the proven PREMO spinning machine series.

Abacus has been an established specialist in custom machinery for sheet metal forming for many years. The company develops and manufactures drawing machines for producing rotationally symmetrical hollow bodies for a wide range of industrial applications. Collaboration with selected technology partners—including Hiwin GmbH—plays a central role in this. “In custom machine building, there are no off-the-shelf solutions. We need partners who can keep up technically and who are always available to us, even when things get critical,” emphasizes Derk Weber, Managing Director of Abacus Maschinenbau GmbH.

The partnership between Abacus and Hiwin has now been in place for over 18 years. After Abacus initially used other guide systems, a casual contact made at a trade show led to an intensive technical exchange, which ultimately prompted the switch to Hiwin linear guides. The deciding factors were not only product quality but, in particular, the reliability of the supply chain, direct technical support, and a partnership based on mutual respect. “Reliability is crucial, especially in times of economic uncertainty. When we have a problem, we don’t want to discuss whether it will be solved, but how quickly,” says Weber. “We’ve experienced this approach from Hiwin for many years.”

Market Pressure as a Driver of Innovation

The impetus for developing the Premo 300 Nova came from specific market observations. At trade shows, it became increasingly clear that while traditional injection molding machines are powerful, they are often oversized for smaller components—both in terms of space requirements and investment costs. “Many of our customers want to invest, but with a sense of proportion,” explains Weber. “Large machines currently often involve too much risk. Small, high-performance solutions are therefore exactly what the market needs right now.”

The Premo 300 Nova was therefore specifically developed for companies that have previously manufactured micro-parts on large extrusion machines with high hourly rates or still extrude them manually, and now want to take the next step toward automation and efficiency. The goal was to develop a compact machine that, despite its significantly reduced dimensions, offers the technological capabilities of larger systems. For the user interface, Abacus relies on its in-house PREMO-Agent control system for the Premo 300 Nova as well—the same system already used in the larger PREMO 600, 1000, and 1200. The intuitive user interface enables a quick start without lengthy training periods—especially for companies transitioning from manual pressing processes to CNC technology. The new machine thus specifically complements Abacus’s existing portfolio and opens up new investment opportunities for both existing and new customers.

Consistently designed for compactness, modularity, and efficiency, the new machine can be integrated into a comparatively small footprint. At the same time, the modular concept allows for customer-specific adaptations, such as additional Z-axes or special options. Modern servomotor technology replaces traditional hydraulic systems and enables precise, energy-efficient operation. “The real challenge during development was safely managing the high process forces within a confined space,” explains Weber. “Compactness must not mean compromising on precision or stability.” Consequently, the requirements for the guide systems used were correspondingly high.

For maximum process reliability

For this reason, Abacus decided to use the Hiwin UR roller guide—the latest generation of Hiwin’s heavy-duty profile rail guides—for the first time in its new machine design. The UR series represents a logical evolution of the proven RG roller guides and was specifically designed for applications in tool and special-purpose machine manufacturing, as well as for highly dynamic, heavy-duty processes.
 
During the forming process, the Premo 300 Nova gradually shapes flat sheets into rotationally symmetrical hollow bodies using rotating forming rollers. In the process, high, shock-like, and pulsating forces act on the machine’s mechanical components. “The UR guide offers exactly the combination of rigidity, load-carrying capacity, and precision that we need for this machine,” explains Derk Weber.

Compared to recirculating ball systems, the UR series uses rollers as rolling elements. The line contact between the roller and the raceway allows for significantly higher loads to be absorbed with minimal elastic deformation. Especially with fluctuating force peaks, such as those that occur during drawing, this ensures high process stability and consistent component quality.
Furthermore, compared to the previous generation, the UR series achieves up to 34% higher static load capacity and up to 19% higher dynamic load capacity. This results in a service life for the guide that is up to 70% longer. This is due to optimized roller geometry, uniform force distribution in the carriage, and overall higher system stiffness. “We deliberately do not design to the absolute limit,” says Weber. “Our customers expect machines that will continue to operate with repeatable performance even after many years. The UR guide gives us the necessary assurance for this.”

Another technical highlight is the integrated magnetic measuring system. The UR roller guide allows for the direct integration of magnetic measuring systems from Hiwin, in which the measuring tape is protected within the rail and the read head is mounted on the carriage.

Previous external tape or cable-pull systems had proven to be mechanically sensitive and a safety concern, particularly with suspended axes. For this reason, Abacus deliberately opted for a second, independent measuring system in addition to the motor control. “Safety is not an optional feature,” emphasizes Weber. “Hiwin’s integrated solution is robust, elegant, and significantly enhances the machine’s functional safety.”

The guidance system is complemented by Hiwin ball screws, which enable precise, backlash-free power transmission and smooth axis movements. Together, they form a comprehensive mechanical system that safely absorbs high process forces while ensuring reproducible positioning accuracy.

A Partnership That Goes Beyond Technology

The design of the linear guides was carried out entirely in-house at Abacus, but was supported from the outset by close technical collaboration with Hiwin. In addition to the online tools provided by the drive technology specialist—such as the design tool and product configurator—direct contact and quick decision-making processes were particularly crucial. “In special-purpose machine construction, there’s no such thing as a standard situation,” emphasizes Tobias Richter, a sales representative at Hiwin GmbH. “Our job is to support designers not only with data sheets, but also with application-specific expertise. Direct dialog is extremely important, especially when it comes to new products like the UR.”

Abacus also sees a clear competitive advantage in this collaboration: reliable delivery times, technical accessibility, and the willingness to develop solutions together are more important to the company than short-term price advantages. “In the end, despite all the digitalization and automation, people remain the crucial interface,” Weber summarizes. “When technology and collaboration function on an equal footing, machine concepts emerge that truly advance the market.”

It is precisely on this basis that both companies see the foundation for further joint projects in the future.

Author: Andrea Blos, Marketing Manager, Hiwin GmbH