Case Study
Simple DNC Data Transfer
KELCH Set Line V244-kOne DNC Transfer to Heidenhain TNC530
Case Study: GA Engineering & KELCH UK
Customer Challenge
Leading power generation equipment manufacturer, GA Engineering, approached KELCH UK seeking a cost-effective and reliable method for transferring tooling data from their newly purchased KELCH Kenova Set Line V244 presetter into their Quasar CNC machine with Heidenhain TNC530 controller.
The customer goals were clear from the outset:
- Reduce setup times
- Eliminate lost production caused by manual tool entry
- Minimise the risk of human error when transferring measured tool data
- Avoid repeated probing of tools at the machine
Manual data entry was slowing down production and introducing unnecessary risk - especially during frequent tool changes.
KELCH UK Solution
KELCH UK proposed a custom DNC post processor designed specifically to transfer tool data directly from the V244 presetter with the latest KELCH kOne measuring software into the Heidenhain TNC530’s tool table (the TOOL.T file).
The post processor was developed and tested in-house by KELCH UK to ensure a smooth, low-risk implementation at GA Engineering. Once validated, it was deployed on-site with minimal disruption to production. Detailed operator training was also delivered by KELCH UK’s experienced technical team, and customised process documentation was left with the customer for future reference.
How the DNC Workflow Operates
Using the KELCH kOne software, the DNC file can be applied to any measuring mode. This enables the operator to transfer either a single tool or an entire tooling sheet directly into the machine control.
The system supports two transfer methods:
1. Manual Transfer
The operator can preset tools ahead of time, review the measured values, then simply trigger the data transfer to the TOOL.T file when ready to complete the tool change.
2. Automatic Transfer
As soon as the single tool or tool list is measured in kOne, the tool data is automatically merged into the TOOL.T file on the CNC machine - no additional operator action required.
Both methods ensure that only the relevant data is overwritten. Existing machine-side values such as wear offsets or additional geometry values remain untouched.
Data Verification & Operator Confidence
Before sending data to the machine, the kOne measuring software can display a preview window. This allows the operator to verify tool numbers, names, and measured values before committing the transfer - adding an extra layer of assurance.
Once confirmed, a single button initiates the output, and the tool data is sent directly to the TNC530.
Customisable Post Processor
The DNC post processor is fully customisable, allowing customers to adjust the format and content to suit their workflow.
Examples include:
- Mapping specific fields from the presetter
- Retaining machine-side wear values
- Adjusting naming conventions
- Supporting both named tools and quick-check measurements
If a tool name is not assigned during measurement, kOne simply prompts the operator to enter a tool number and name before transfer.
Customer Results
GA Engineering achieved measurable improvements immediately after implementation:
- Significant reduction in setup times
- Elimination of manual data entry errors
- Faster tool changes and reduced machine downtime
- No need to individually probe each tool during every setup
The automated DNC workflow now provides a consistent, repeatable, and error-free method of populating the TOOL.T file - improving both productivity and process reliability.
Next Steps: Expanding DNC Connectivity Across the Site
Following the success of the initial phase of this project, GA Engineering are now planning to extend DNC connectivity between their KELCH V244-kOne presetter and additional CNC machines across their facility. This includes a diverse range of Mori Seiki and Mazak machines, each of which will benefit from the same streamlined, error-free data transfer process already proven on the Heidenhain TNC530.
KELCH UK Data Transfer Solutions
KELCH UK provides a comprehensive portfolio of data transfer systems designed to ensure efficient, secure, and repeatable communication between presetters and CNC machines. Whether you require a simple point-to-point transfer or a fully automated, multi-machine workflow, our solutions can be tailored to your exact requirements.
CONTACT US today to discuss your specific DNC requirements.
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