Monitoring & metering
Besides tool wear, what else does the system monitor?
Monitoring the tool is our solution’s main focus. But there are, of course, other valuable side effects. For instance, the system can protect the machine even when it is not cutting: sometimes the tool moves without actually cutting during tool positioning with very high feed rates. The force of the machine might then lead to a collision of the tool with the machine, which results in severe damages. Our solution recognises this fast movement and stops the machine before anything happens. Another example: one of our customers recently noticed that the measuring signal was very small – much smaller than the defined window. There had to be something wrong. They checked and found out that the dimensions of the parts that had been loaded were slightly off. In other words: monitoring systems are an in- direct way of controlling the incoming and produced part quality. Therefore, other pre- and post- quality measurements in place can be reduced, thus lowering costs.
Your system is not the first on the market to monitor machining processes. Can you tell us, what differentiates the Kistler solution from other tried and tested options?
The biggest difference lies in the high frequency that is inherent to piezoelectric sensors. Strain gauge technology is another cost-effective and established option. However, there are shortcomings in capturing the high dynamics of many machining processes. A tool of course wears with time. Yet the moment it breaks may come very suddenly. Just today a customer sent us some data and an image. They saw that all of a sudden, and only for a very brief moment, the measuring curve exceeded the limit. It was just a small peak, after which the curve went back to normal. But since the alert went off and the machine stopped, they looked at the tool, and, indeed, it was chipped. In cases such as this, the piezoelectric sensor really plays out its strengths.
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Machining is part of many manufacturing industries. Who would profit most from this solution? And who wouldn’t?
With our first package consisting of a sensor, the monitoring system, cables and accompanying software, we focus on clients who produce small to medium-sized parts such as bearing components, automotive components, medical parts, small mechanical parts such as screws and watch components in mass production. A limiting factor here is cycle time. We can measure fast but even a piezoelectric sensor has its limits. The age of the machine, in contrast, is never an issue. Of course, when planning a new line or buying new machines, including automation technology is the standard nowadays, and there will be room for measurement technology. But with our package, we can also retrofit older machines. Our solution is flexible and it does not matter which MES you use. The goal is to make the advantages of automation available at comparably low entry costs.
What is the next step? Are you already planning to offer your solutions to clients who produce bigger parts as well?
Yes, we are already preparing a corresponding package. Another idea that we are working on is to make the system more intelligent and go beyond measuring and monitoring. In some specific cases, we already aim to also enable the system to compensate for certain errors of the machine, for instance by regulating the cutting speed, feeds and cutting depths. This will allow our customers to achieve even better product quality.
Kistler
www.kistler.com August 2024 Instrumentation Monthly
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