Digital intelligence for machine tool protection
Collisions resulting from operational errors are at the top of the list of things to be avoided and can cause significant damage on the workpiece, spindles, and sometimes even the whole machine. This, in turn, will lead to a cessation of production, as well as many additional costs, particularly the cost of time. Do you want to learn how to detect operational errors and prevent collisions before they occur?
Here are four ways that can help you to avoid potential collisions by eliminating operational errors. Each of these ways will help you to reduce your cost and ensure continuity of your production as well.
Requirement: Running an NC code derived from an external CAM system directly on the machine tool poses many risks. CAM systems control the toolpaths they generate, so an operational error is unlikely to be detected. A simulation where the factors that can lead to a possible collision, e.g. kinematic structure, job setup, transformation behavior, etc., are active, is especially necessary for companies that produce heterogeneous workpieces.
Solution approach: A complete digital twin that can simulate material removal on the kinematic 3D model, covering the NC, PLC and HMI behavior of the machine, including tooling and clamping enables end-to-end protection of all operations against possible collisions.
Our Solution: The Run MyVirtual Machine suite enables users to have a complete digital twin of their machine tool provided by the machine builder. Thus, NC programmers can simulate and verify part programmes offline at a PC in the work preparation department, without stopping the machine from making chip
Requirement: As batch-size quantities become smaller and more flexible, it is crucial to reduce setup times and move automation systems to leaner production schedules. Today, companies are developing both manual and automated approaches that require visual inspection of the machining area against incorrectly mounted fixtures, workpieces or processes which are uniquely executed by humans. The combination of enhanced operator responsibility and increased visual inspections leads to failures, such as increased scrap and operating costs.
Solution approach: A system consisting of a lightweight camera and artificial intelligence (AI) helps to reliably and accurately monitor workpieces and setup environments in order to ensure the quality of the machining process.
Our solution: The Protect MyMachine /Setup Edge application operates in tandem with a cloud-based application, Manage MyAI, in order to deliver a closed loop ecosystem for gathering training data, training AI models, and deploying models back into the industrial automation scenario.
Requirement: Even in the most well-structured processes, operational errors can cause machine tools to collide. Such errors include those in manual movements and interventions that cannot be performed offline. Moreover, the tool lengths and reference points that active on the machine may differ from the specified ones. When there is no real-time protection system, overcaution in trial cuts can also prolong the process and cause stress.
Solution approach: Such operating and programming errors can be prevented before they occur if they can be simulated on the 3D kinematic model which works in synchronization with the connected machine tool.
Our solution: The Protect MyMachine /3D Twin Edge application allows users to create and place the job setups on the machine tool’s 3D Kinematic model to prevent any collisions during operation.
Requirement: Especially in the machining of casting materials, tools may be exposed to loads that CAM programs cannot predict or residual materials from previous operations may endanger subsequent operations. As a result, these mistakes can result in further scraps and serious tool and spindle failures.
Solution approach: A real-time collision monitoring system based on external sensors can detect any anomaly in case of overload or collision and stop the machine before any damage occurs.
Our solution: Collision detection (VCM) is a microprocessor-based, real-time system that can analyze vibration data to either predict or prevent pending failures, thus reducing the costs associated with the breakdown of machine components such as spindles, axis motors, bearings, cutting tools, and fixtures. The system is also designed to enable the user to identify potential problems and take preventive actions based on deviations from the machine’s “healthy” vibration signature.