Optimization of production processes through rotating windows

Spinning windows rely on the principle of centrifugal force. Through rapid rotation, outward forces are generated from the center of rotation, effectively clearing the viewing surface. This phenomenon can be likened to the forces experienced on a spinning chain carousel.

Centrifugal Force in Action

Spinning windows utilize an electric motor to rapidly spin the circular disk. As flying cooling lubricant droplets or metal chips come into contact with the spinning window, they are immediately forced outwards. This self-cleaning mechanism ensures a clear view at all times.

To maintain the tightness of these self-cleaning windows, sealing air is often used. However, not all manufacturers provide this feature as an option.

Looking for more details on how spinning windows work or how to install them?

The concept of spinning windows in machine tools was inspired by ocean-going shipping. In rough seas, strong winds and high waves often cause spray, making visibility on the bridge of a ship extremely difficult.

This situation is quite similar to the challenges faced in machine tools. To ensure the helmsman maintains a clear view despite these conditions, specially designed “windshields” have been used on ships for many years.

From Ocean-going Ship To Machine Tool

In the 1980s, an employee at Autz + Herrmann GmbH, from which Rotoclear GmbH would later be spun off, realized that this principle could also be applied to improve visibility within machine tools. It quickly became clear that this idea held tremendous potential. As a result, the team collaborated to design, develop, and refine the ideal solution for machining processes — ultimately leading to the creation of the first spinning window for machine tools in 1983. A true world first at the time.

Continuous Development and Optimization

In the following years, this product was not only sold worldwide but also continuously improved. In 1988, the product was enhanced with a safety glass to provide better protection for machine operators against splinters and chips. Then, in 2008, the next product generation reduced the installation depth even further, simplifying the integration into machine tools.

The Rotoclear S3 Sets New Standards

In 2013, after three years of product development, the next generation was introduced: the new Rotoclear S3 spinning window. Not only does it impress with a significantly reduced installation depth, but it also features a completely new drive concept, revolutionizing the product design.

With the removal of the bar in this model, the Rotoclear S3 provides users with an entirely unobstructed view inside the machine.

This pioneering achievement further underscores Rotoclear’s technological leadership in the market – literally making the competition look outdated.

The Role of Spinning Windows in Machining Optimization

Why are thousands of machine operators and OEMs worldwide convinced by the principle of the rotating window? Quite simply, because a clear view is more than just a convenience – it enables and simplifies a wide range of machining processes. Moreover, it forms the essential foundation for the continuous improvement of machining processes as part of a manufacturing company’s Continuous Improvement Process.

Next, we will take a closer look at the various stages of the production process where rotating windows are especially important.

The time and cost savings of a spinning window are most noticeable during the retraction process, starting with the number of door openings.

Less Interruptions Mean Higher Productivity

Without a spinning window, the infeed process must be repeatedly interrupted, as the door needs to be opened to visually check the correct positioning of the workpiece and tool. By eliminating these interruptions, the loading process becomes significantly faster, which in turn boosts productivity.

There are also safety considerations to take into account. Every time the machine is entered, there is a safety risk for the employee. In other words, the fewer times the machine has to be accessed, the lower the risk of accidents at work.

Less Tool Wear Due To Spinning Window

But that's not all. When a machine tool lacks a spinning window, machining processes are sometimes initially run without cooling lubricants, just to visually assess the process during run-in. However, operating without cooling lubricants leads to significant tool wear, resulting in high costs.

The spinning window allows operators to use cooling lubricants from the very first part, significantly reducing tool wear.

If the tool and workpiece collide unintentionally, the worst-case scenario occurs — a crash! The process goes completely out of control. The consequences can be devastating not only for the tool and workpiece, but also for the machine, causing massive damage.

Extend Service Life: Identify Irregularities and Deviations in Advance

When machine operators have a clear view of the tool and workpiece from the outside, they can detect irregularities or deviations at an early stage, allowing them to react promptly and prevent crashes and their devastating consequences before they occur. Field reports show that after installing spinning windows, the number of crashes has decreased significantly.

This, in turn, leads to fewer breakdowns and reduced downtimes, which directly impacts the company's productivity.

Whether it’s about minimizing tool wear, ensuring quality, optimizing chip flow, or improving the linking of machining steps, anyone looking to continuously optimize their machining processes must first identify where optimization potential lies. The ability to observe the machining process from the outside is a crucial prerequisite for this.

Optical Information as a Basis for Optimization

Visual feedback allows for the collection of specific data and helps to understand how certain parameters impact product quality or tool wear. These observations can then be used for analysis, enabling the identification of recurring patterns and the implementation of systematic improvements in the production process.

Increase Motivation for Process Optimization

Employee motivation plays a key role in this process: when machine operators can observe the processes directly, it strengthens their commitment and responsibility for work quality. They are more motivated to identify potential improvements and make suggestions that can lead to increased efficiency or reduced errors.

Whether during the run-in process or series production, constant interruptions to the machining process due to door openings not only reduce productivity, but also introduce significant safety risks. Every time the work area is accessed for visual inspection, there are hazards, such as slippery cooling lubricant on the floor after machining.

No More Need to Bypass Safety Precautions

To avoid constant interruptions and still be able to observe the machine, older machines without spinning windows sometimes bypass crucial safety measures that automatically stop the machine when the door is opened. However, leaving the door open during processing presents a significant safety risk: employees can be struck by chips, splinters, or broken tools — with potentially fatal consequences!

With a spinning window, processes no longer need to be interrupted for visual inspections, and the door does not need to be opened. It allows continuous monitoring of all processes from the outside — safely behind the machine window!

When we talk about process optimization, we must not overlook the regular cleaning effort. Instead of constantly cleaning the entire machine window from cooling liquid and chip residues to maintain visibility, a rotating window only requires a cloth to be held against the spinning window from the inside to clean it. This significantly minimizes the cleaning effort.

Machine Windows Live Longer

As harsh cleaning agents can also damage the machine window over time, using a spinning window can help extend its service life — leading to further significant cost savings.

More and more companies are becoming aware of the benefits of spinning windows for process optimization in machine tools. It’s no surprise that all major OEMs are now incorporating spinning windows as essential components in their machines — driving a growing demand for them. Manufacturing companies that still use older machines are often retrofitting these windows. There are various options for doing so, and we are happy to offer you advice on this at any time, without obligation.

But what does the future hold for these products? What further developments can be expected? Rotoclear — the innovation and technology leader in the field of spinning windows — is currently developing the next product generation with the Rotoclear S4.

In addition to small optimizations, the product developers and engineers have the major goal of reducing the installation depth of the product even further, allowing the spinning window to be integrated even more seamlessly into the machine window in the future.

We can therefore look forward to seeing what the spinning window of the future will look like.