2022 Consortium for Self-Aware Machining and Metrology

Optimize MyMachining /AdaptiveControl
Higher machine productivity with OmativeTM technology
Analyze MyWorkpiece /ToolMonitor
Effective and robust tool breakage detection for Sinumerik
Page 1 Unrestricted | © Siemens 2022
Page 1

Introduction
Who is Pure Precision?
What is Siemens’ ACM Portfolio?
Unrestricted | © Siemens 2022
Page 2

Who is Pure Precision?
Pure Precision is a boutique consultancy located in Charlotte, North Carolina. Our focus is boosting
manufacturing effectiveness for our nationwide clients, hedging against the current skilled labor shortages,
employee turnover, and supply chain disruptions. These issues present challenges in keeping a company
efficient and profitable. Sometimes companies have lost their way with lean and need a boost, sometimes
others look to make significant gains with Industry 4.0 and digital transformations.
We approach an engagement with a few diagnostic and strategy questions. What’s really preventing
operations from performing? Where are the sources of dysfunction? How do they manifest on the shop floor?
What’s the gap to best practice? What does good performance look like?
We use a proven solution designs to solve the issues. Where should we lean in and how should we lean in?
What are the key priorities, the critical few that will move the needle in terms of performance? How do we
succeed in change management. How do we effectively lead change in a manufacturing environment? Who
are the main personas? What do they care about? What are their responsibilities? How are they rewarded?
Pure Precision has led successfully engagements for companies nationwide, from the shopfloor to the
boardroom, working with various size companies, from 20 up to well over 5000 employees
Page 3

Pure Precision
Siemens Partners are leaders in their domains and leverage the Siemens open platform to provide
a comprehensive set of integrated solutions that help expand the ecosystem and provide
customers with several solutions that are best in class.
These partners help expand the Siemens solution portfolio and enable customers to solve business
challenges by offering complementary software, hardware, and technology.
Additionally, Siemens Partners augment the solution portfolio by adding functionality, expertise, and
flexibility, which in turn provides customers with the ability to tailor solutions to best fit their needs
without being confined to using a specific product or vendor.
Pure Precision is proud to be a part of the Siemens Solution Partner family
Page 4

What is Siemens’ ACM Portfolio?
• monitors the machine spindle power and automatically adjusts the feed rate to its highest feasible level
during each operation.
• is an advanced adaptive control system, designed to operate with a variety of CNC machines to enhance
machine productivity.
• is a real-time monitoring application that detects cutting tool breakage, abnormal cutting conditions, and
excessive tool wear during machining process and immediately stops the machine.
Machine Tool Control Agnostic
• SINUMERIK controls as well any other industry CNC machine tool control (FANUC, Mitsubishi, etc)
Page 5

OmativeTM technology by Siemens
The original adaptive control technology
Page 6

Siemens’ ACM Technology Evolution
1990 2000 2018
2010
Technology
development
From scientific
theory into real-
world application
1996 – 2004
Expansion into
additional applications
and technologies
2013 – 2015
Real-time tool
wear & breakage
monitoring
technology
Siemens
Technology acquisition
2021
Start rolling out
GEN2 products
1996
Optimill,
1st adaptive control
product
2004
2nd adaptive control
product
2015
ACM, with tool
breakage monitoring
2020
25+ years of Market Experience
1
Siemens Technology Acquisition 2018
2
Continuous Technology Development
3
Page 7

Optimize MyMachining /AdaptiveControl Benefits
Higher Productivity
Manufacture more parts in
less time with no changes in
existing process
Increase process stability
with runtime cutting tool
protection
Contain operating costs
increasing machine
productivity
Page 8

Analyze MyWorkpiece /ToolMonitor: Reliable breakage detection at the lowest TCO
New algorithms for most
challenging features
• Small tools
• Short cutting times
Full automation for
increased reliability
• Fewer false positives
• Fewer false negatives
Built-in co-existence
with adaptive control
• One-time installation
• Immediate activation,
zero machine downtime
Page 9

How Adaptive Control
Works
Page 10

OMM /AdaptiveControl
Control sequence
Shorten non-productive machining time
Reduce feed rate to ensure cutting tool is protected
during material entrance
Increase feed rate depending on spindle load
Reduce feed rate in extreme cutting conditions to avoid
tool breakage
Vary feed rate in accordance with spindle load
Minimize non-productive machining time during air
cutting
1
2
3
4
5
6
programmed (constant) feed
adaptive feed control
Page 11

Using OMM /AdaptiveControl
In 3 simple steps
Page 12

AC “operation”
Operation = <tool, speed>
OMM /AC optimizes operation
Operation may run multiple times
(instances) during one workpiece
machining
Actions without spindle rotation are NOT
operations (e.g. measurements or tool
change)
Page 13

Step 1: training
Automatic recording of
reference load profiles
Automatically collect reference
permissible load profiles for all operation
for any new NC program
Does not modify feed rate, override dial
must be set at 100%
Some operations are filtered out
automatically as not suitable for
optimization (e.g. finishing with very low
load variability)
Page 14

Step 2: user reviews settings and authorizes optimization
Flexible optimization
strategies
User can disable optimization of each
operation at any time(*)
Technologist can select specific
optimization strategy for individual tools
and operations
Overload alarm can be set to prevent tool
breakage, workpiece damage, and detect
tool wear
(*) Only operations that are suitable for adaptive control appear in the list
Page 15

Step 3: optimization
Dynamic productivity
Protect the cutting tool on material
entrance
Reduce cycle time when the tool is not
loaded
Trigger alarm to prevent tool breaking on
overload
Page 16

Page 17

Using AMW /ToolMonitor
In 3 simple steps
Page 18

Step 1: training
Automatic recording of
reference load profiles
Automatically collect reference load
profiles for all operation for any new
NC program
Feed and speed overrides must be
set at 100% to ensure validity of
reference profiles.
Deviations from 100% settings will
require another workpiece to be
machined in training mode
Page 19

Step 2: user chooses monitoring mode based on tool breakage risk profile
Monitoring profiles
ToolMonitor automatically detects whether
the tool can be monitored for breakage (*)
User can choose monitoring mode
(anomaly or breakage) for every tool
Technologist decide on monitoring
strategy by selecting appropriate
sensitivity levels. Higher sensitivity is
suitable when the risk of missing a tool
breakage leads to bigger productivity
losses
(*) Noise in the spindle signal can lead to monitored signal to be
too weak for reliable breakage monitoring. Such tools will be
monitored for anomaly (overload) only. This automation avoids
wasting time on configurations that will result in many false
alarms and reduce productivity.
Page 20

Step 3: monitoring
Reliable operation
Sensitivity down to 1mm diameter
tools and cutting that lasts less than a
second
The system monitors for breakage
only those tools that can be reliably
tracked using load signal  minimize
false positives
Autonomous measurement of all
critical machine signals  no need in
human intervention to adjust settings
to avoid false alarms
Page 21

Examples
Page 22

Page 23

Page 26

Tool: HARVI Ultra 8X
ACM
OFF
ACM
ON
1615
1315
[CELLRAN
GE]
0
200
400
600
800
1000
1200
1400
1600
1800
ACM OFF ACM ON
Cycle
Time
[s]
• Tool impact protection
• Tool overload protection
 Improved tool life
Page 27

Page 28

Tool: KOR6 End Mill
ACM
OFF
ACM
ON
4874
3836
[CELLRAN
GE]
0
1000
2000
3000
4000
5000
6000
ACM OFF ACM ON
Cycle
Time
[s]
• Shorten non-cutting machining
time
 Reduced cycle time
Page 29

AMW /ToolMonitor
Page 30

AMW /ToolMonitor
2.5mm drill in aluminum
Page 31

Reduce tool breakage
Minimize unplanned downtime
Benefits
Cycle time reduction
Tool life extension
Tooling cost reduction
Conclusion
Page 32

Page 33
Question and Answer Session

Gus Gremillion
Solutions Consultant – Machine Tool Digitalization
Siemens Industry Software Inc.
+1 (470) 216-3572
august.gremillion@siemens.com
Page 34
Michael Unmann
Founder and CEO
Pure Precision OEE LLC
+1 (570) 205-6781
michael.unmann@pureprecisionoee.com
Presenters - Optimize MyMachining /AdaptiveControl
2022 Consortium for Self-Aware Machining and Metrology

2022 Consortium for Self-Aware Machining and Metrology

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