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TMAC System

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The CEI TMAC System protects machine tools, tooling, and workpieces by detecting worn & broken tooling on CNC machine tools in real time. Adaptive control machining can reduce part cycle times and ...

The CEI TMAC System protects machine tools, tooling, and workpieces by detecting worn & broken tooling on CNC machine tools in real time. Adaptive control machining can reduce part cycle times and improve tool life. Coolant and spindle speed monitoring is also available.

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TMAC System TMAC System Presentation Transcript

  • Advanced Tool Condition
    Monitoring and Control
  • What is TMAC™
    • TMAC™ is a system that protects your tooling and machine
    • Provides valuable information about your cutting process, by measuring true motor hp for spindle and feed axis it determines when a tool is worn or broken and commands the machine to take corrective action before tools or parts are destroyed!!
  • Basic Components of TMAC™
    Main Controller
    Horsepower Transducer
    TMS Display Software
  • Basic Principals
    • Monitors true horsepower instead of current as most CNC load meters do.
    • Measures the horsepower of a new tool during a cut
    • Determines whether a tool is worn or broken by comparing the cutting horsepower to user programmed limits
    • Adaptive control overrides the feed rate automatically to maintain constant horsepower
  • Why measure horsepower
    Horsepower is linear over the range of the motor, providing a very stable and accurate indicator of spindle motor
    Current, is non-linear over the range of the motor due to power factor
    Most tool monitors provided by machine tool builders measure current
    Horsepower
    Current
    Current
    Horsepower
    0%
    50%
    100%
    Motor Load
  • Dual Range Transducer
    When the transducer is set to the full range of the motor the effect of a small tool is not as easily determined.
    Drill cutting
    With the dual range transducer set at a smaller range the effect of the tool is much easier to determine
    Drill cutting
  • Measuring Horsepower
    The Tool Monitor separates the cutting horsepower from the horsepower required to idle the motor under no load
    Start Signal
    Actual Cutting HP
    Learned HP
    Horsepower
    Idle HP
    Time
    This technique eliminates any effect from the spindle on the measured horsepower
  • Using Horsepower
    Our tool monitoring works on the simple concept that the horsepower used by a tool increases as it gets dull
    EXTREME
    Horsepower
    WEAR
    Part#
    1
    10
    15
    20
    25
    28
    29
  • TMAC™ Includes
    • Tool Monitoring
    • Adaptive control
    • Coolant Flow and Spindle Speed Monitoring
    • Network connectivity
    • Data logging
    • Alarm reporting
  • Main Controller
    • Uses a real-time operating system
    • Handles all communications to the CNC control
    • Handles all analog sensor inputs, all digital inputs and outputs
    • It can run standalone without any PC connected
    • Even if the PC crashes, the main controller will continue to monitor and adaptively control the machine
  • Horsepower Transducer
    • Measures true horsepower
    • Electrically sums the current and voltage reference
    • Provides a 0-10 Volt signal respective of the horsepower
    • Has two ranges. One for the entire motor range and a lower range to allow the monitoring of smaller tools
  • TMS Display Software
    • Is the user interface for setting up the system
    • Allows a constant 30 second window of all monitoring and adaptive control
    • Can run on a customer supplied PC
    • Stores data for later analyses with TMS Viewer
    • Allows the viewing of alarmhistory
  • Tool Monitoring in Action
    • The system learns the horsepower of each tool
    • The user sets limits for Extreme, Wear and Undercut for each tool (any combination)
    • The CNC starts the system monitoring for each tool
    • A variety of actions can take place when a limit occurs
  • How the Limits Work
    Wear Limit
    • Stop after cutting
    • Call redundant tool
    Extreme Limit
    • Retract the tool
    • For a tap (Okuma only) unwind out of material
    • Send email or text message to appropriate person
    Start Signal
    EXTREME LIMIT
    WEAR LIMIT
    Horsepower
    Nominal HP
    UNDERCUT LIMIT
    Undercut Limit
    • Any action that can be taken for Wear and Extreme limits
    Idle HP
    Time
  • Adaptive Control
    • Each tool needs a desired horsepower. This can be programmed or learned
    • The range of allowable override is set
    • (0-255% for most controls)
    • Adaptive control is started by the CNC and the feedrate override control is switched to the TMAC
    • The system will modify the feedrate automatically to maintainconstant horsepower
  • Adaptive Control Example
    Applied Feedrate
    Measured HP
  • Example Drilling Process
    • The lighter areas are hard spots in the material.
    • The first hole is drilled without using adaptive control
    • Red represents tool breakage
    • The second cycle uses adaptive control to protect your drill
    • Without adaptive control, the drill would have broken when it hit the hard spot
  • Milling a Rough Casting
    Cast or forged parts typically
    have varying surfaces
    This forces manufacturers to make several facing cuts to get the desired
    dimension and finish without breaking the tool
    • Two Rough Castings
  • Advantage of Adaptive Control
    • Without Adaptive Control
    • Using Adaptive Control
  • Time Increment Limits
    • Allows a series of limits to be programmed for a single tool
    • The switch to each set of limits occurs by specified time after the first call from the CNC
    • In the learn mode, each time segment learns a separate peak horsepower
    • Any number of segments can be used for each tool
    • An excellent solution for step drills and taps
  • Time Increment Limits
    Tap back to forward
    Tap Reversing
    Tap Cutting
  • Advantages of Time Increment Limits
    • Tapping
    • Multiple holes with the same drill but varying material thicknesses
    • Deep hole drilling
    • Turning applications with variations in diameter
    • Contour milling
    • Step Drills
  • Slope Monitoring
    • Slope monitoring
    • Allows horsepower limits based on the rate of change of a cut
    • Each slope can be set in the positive or negative direction
    • Using our time slice technology, the slope can change at any time during the cut
  • How Slope Monitoring Works
    • The green line shows nominal cutting horsepower
    • The white line shows actual cutting horsepower
    • The red and yellow lines are the extreme and wear limits respectively
    • The Blue line is the under-cut limit
    8/6/2009
    Caron Engineering TMS System7
    24
  • Using Slope and Normal
    This example shows that using time slicing, normal monitoring and slope monitoring can be used during a cut
    Normal
    Monitoring
    Slope
    Monitoring
  • Coolant Flow Monitoring
    • Up to (4) coolant flow/pressure sensors can be used.
    • The user sets the minimum flow/pressure allowed per tool
    • If the coolant flow/pressure drops below this level, an alarm is generated
    • All coolant flow/pressure is also graphed and can be reviewed with TMS Viewer
    • A variety of flow/pressure transducers are available depending on the maximum pressure and minimum flow rate to be monitored
  • Coolant Flow 1
    Coolant Flow 2
    Coolant Flow 3
    Coolant Flow 4
    Coolant Flow 3 ALARM
  • Data History
    • The 500 most recent events are saved and displayed
    • All monitoring data can be saved and later viewed with TMS Viewer
    • Event can also be logged to a file locally or on a network
  • TMSViewer
    • Displays a stored file of collected tool monitor data
    • Excellent tool for analysis
  • TMAC LiveView
    • Remote view of any TMAC system in the shop
    • Allows the user to create separate data files
    • You see what the operator sees
  • Conclusion
    The TMACTM from Caron Engineering Inc. is a very sophisticated, yet easy to use system for monitoring and controlling your tools. It has a quick return on investment and can also provide extensive analysis of your cutting process.
  • Some TMAC7 Customers….
    • Smiths Aerospace
    • General Dynamics
    • Husky Injection Molding
    • Okuma America
    • Webster Valve
    • Orenda Aerospace
    • MTU Aero Engines
    • Rockwell International
    • Stryker HowmedicaOsteonics
    General Electric Aircraft
    Smith & Wesson
    Pratt & Whitney Aircraft
    General Motors
    Sikorsky Aircraft
    Smith & Nephew
    Melroe Bobcat
    Arvin Meritor
    Volvo Aerospace
    NyproMold, Inc.
  • To Contact Us
    Caron Engineering Inc.
    P.O. box 1529
    1931 Sanford Road
    Wells, ME 04090
    (207) 646 6071
    www.caron-eng.com
    Email: marketing@caron-eng.com