Amidst cost pressures, uncertainty and rising demands, the special-purpose machinery sector requires solutions that are bendable, 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 within the tried-and-tested 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 spinning machines for the production of 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,” emphasises Derk Weber, Managing Director of Abacus Maschinenbau GmbH.

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

Market pressure as a driver of innovation: The path to the Premo 300 Nova
The impetus for developing the Premo 300 Nova arose from specific market observations. At trade fairs, it became increasingly apparent that whilst traditional extrusion 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 high a risk. Small, powerful solutions therefore strike exactly the right chord.”
The Premo 300 Nova was therefore specifically developed for companies that have previously manufactured micro-parts on large forming machines with high hourly rates, or still form them manually, and now wish to take the next step towards automation and efficiency. The aim was to develop a compact machine that, despite significantly reduced dimensions, offers the technological performance of larger systems. On the operator side, Abacus has also opted for its in-house PREMO-Agent control system in the Premo 300 Nova, which is already used in the larger PREMO 600, 1000 and 1200 models. The intuitive user interface enables a quick start without lengthy training periods – particularly for companies switching from manual pressing processes to CNC technology. The new machine thus specifically complements Abacus’s existing portfolio and opens up new investment opportunities for existing and new customers.

Consistently sized 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 servo motor technology replaces traditional hydraulic systems and enables precise, energy-efficient operation.
“The real challenge during development was to safely manage the high process forces within a confined space,” explains Weber. “Compact must not mean compromising on precision or stability.”
The demands placed on the guide systems used were correspondingly high.

Heavy load roller guides for maximum process reliability
For this reason, Abacus opted for the first-ever use of the HIWIN UR roller guide in the new machine concept – the latest generation of heavy-load linear guideways from HIWIN. The UR series represents a logical further development of the proven RG roller guides and was specifically designed for applications in tool and special-purpose machine construction, as well as for highly dynamic heavy-load processes.
During the spinning process, the Premo 300 Nova gradually forms flat sheets into rotationally symmetrical hollow bodies using rotating spinning rollers. In the process, high, impact-like and pulsating forces act on the machine’s mechanics. “The UR guide offers precisely 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 track allows significantly higher loads to be absorbed with minimal elastic deformation. Particularly in the case of fluctuating force peaks, such as those occurring during spinning, 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 one guide that is up to 70% longer. This is due to optimised roller geometry, even force distribution within the block, and overall higher system rigidity.
“We deliberately do not design to the absolute limit,” says Weber. “Our customers expect machines that will still operate with reproducible results even after many years. The UR guide gives us the necessary assurance to achieve 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 encoder is mounted on the block.
Previous external tape or cable pull systems had proven to be mechanically sensitive and a safety hazard, particularly on 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,” emphasises Weber. “HIWIN’s integrated solution is robust, elegant and significantly enhances the machine’s functional safety.”
The guide system is complemented by ballscrews from HIWIN, which enable precise, backlash-free power transmission and smooth axis movements. Together, these elements form a comprehensive mechanical system that safely absorbs high process forces whilst ensuring reproducible accuracy in positioning.

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 sizing tool and product configurator, direct contact and short decision-making processes were particularly crucial.
“In special-purpose machine construction, there is no such thing as a standard situation,” emphasises Tobias Richter, field sales representative at HIWIN GmbH. “Our task is to support designers not only with data sheets, but with application-specific know-how. Direct dialogue is extremely important, particularly with new products such as the UR.”

Abacus also sees a clear competitive advantage in this collaboration: reliable delivery times, technical accessibility and a willingness to develop solutions together are more important to the company than short-term price advantages.
“Ultimately, despite all the digitalisation and automation, people remain the crucial interface,” summarises Weber. “When technology and collaboration work on an equal footing, machine concepts emerge that truly drive the market forward.”
It is precisely on this basis that both companies see the foundation for further joint projects in the future.

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