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 improve tool life. Coolant and spindle speed monitoring is also available.

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TMAC System

  1. 1. Advanced Tool Condition <br />Monitoring and Control<br />
  2. 2. What is TMAC™<br /><ul><li>TMAC™ is a system that protects your tooling and machine
  3. 3. 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!!</li></li></ul><li>Basic Components of TMAC™<br />Main Controller<br />Horsepower Transducer<br />TMS Display Software<br />
  4. 4. Basic Principals<br /><ul><li>Monitors true horsepower instead of current as most CNC load meters do.
  5. 5. Measures the horsepower of a new tool during a cut
  6. 6. Determines whether a tool is worn or broken by comparing the cutting horsepower to user programmed limits
  7. 7. Adaptive control overrides the feed rate automatically to maintain constant horsepower</li></li></ul><li>Why measure horsepower<br />Horsepower is linear over the range of the motor, providing a very stable and accurate indicator of spindle motor<br />Current, is non-linear over the range of the motor due to power factor<br />Most tool monitors provided by machine tool builders measure current<br />Horsepower<br />Current<br />Current<br />Horsepower<br />0%<br />50%<br />100%<br />Motor Load<br />
  8. 8. Dual Range Transducer<br />When the transducer is set to the full range of the motor the effect of a small tool is not as easily determined.<br />Drill cutting<br />With the dual range transducer set at a smaller range the effect of the tool is much easier to determine<br />Drill cutting<br />
  9. 9. Measuring Horsepower<br />The Tool Monitor separates the cutting horsepower from the horsepower required to idle the motor under no load<br />Start Signal<br />Actual Cutting HP<br />Learned HP<br />Horsepower<br />Idle HP<br />Time<br />This technique eliminates any effect from the spindle on the measured horsepower<br />
  10. 10. Using Horsepower<br />Our tool monitoring works on the simple concept that the horsepower used by a tool increases as it gets dull<br />EXTREME<br />Horsepower<br />WEAR<br />Part#<br />1<br />10<br />15<br />20<br />25<br />28<br />29<br />
  11. 11. TMAC™ Includes <br /><ul><li>Tool Monitoring
  12. 12. Adaptive control
  13. 13. Coolant Flow and Spindle Speed Monitoring
  14. 14. Network connectivity
  15. 15. Data logging
  16. 16. Alarm reporting</li></li></ul><li>Main Controller<br /><ul><li>Uses a real-time operating system
  17. 17. Handles all communications to the CNC control
  18. 18. Handles all analog sensor inputs, all digital inputs and outputs
  19. 19. It can run standalone without any PC connected
  20. 20. Even if the PC crashes, the main controller will continue to monitor and adaptively control the machine</li></li></ul><li>Horsepower Transducer<br /><ul><li>Measures true horsepower
  21. 21. Electrically sums the current and voltage reference
  22. 22. Provides a 0-10 Volt signal respective of the horsepower
  23. 23. Has two ranges. One for the entire motor range and a lower range to allow the monitoring of smaller tools</li></li></ul><li>TMS Display Software<br /><ul><li>Is the user interface for setting up the system
  24. 24. Allows a constant 30 second window of all monitoring and adaptive control
  25. 25. Can run on a customer supplied PC
  26. 26. Stores data for later analyses with TMS Viewer
  27. 27. Allows the viewing of alarmhistory</li></li></ul><li>Tool Monitoring in Action<br /><ul><li>The system learns the horsepower of each tool
  28. 28. The user sets limits for Extreme, Wear and Undercut for each tool (any combination)
  29. 29. The CNC starts the system monitoring for each tool
  30. 30. A variety of actions can take place when a limit occurs</li></li></ul><li>How the Limits Work<br />Wear Limit<br /><ul><li>Stop after cutting
  31. 31. Call redundant tool</li></ul>Extreme Limit<br /><ul><li>Retract the tool
  32. 32. For a tap (Okuma only) unwind out of material
  33. 33. Send email or text message to appropriate person</li></ul>Start Signal<br />EXTREME LIMIT<br />WEAR LIMIT<br />Horsepower<br />Nominal HP<br />UNDERCUT LIMIT<br />Undercut Limit<br /><ul><li>Any action that can be taken for Wear and Extreme limits</li></ul>Idle HP<br />Time<br />
  34. 34. Adaptive Control<br /><ul><li>Each tool needs a desired horsepower. This can be programmed or learned
  35. 35. The range of allowable override is set
  36. 36. (0-255% for most controls)
  37. 37. Adaptive control is started by the CNC and the feedrate override control is switched to the TMAC
  38. 38. The system will modify the feedrate automatically to maintainconstant horsepower</li></li></ul><li>Adaptive Control Example<br />Applied Feedrate<br />Measured HP<br />
  39. 39. Example Drilling Process<br /><ul><li>The lighter areas are hard spots in the material.
  40. 40. The first hole is drilled without using adaptive control
  41. 41. Red represents tool breakage
  42. 42. The second cycle uses adaptive control to protect your drill
  43. 43. Without adaptive control, the drill would have broken when it hit the hard spot</li></li></ul><li>Milling a Rough Casting<br />Cast or forged parts typically<br />have varying surfaces<br />This forces manufacturers to make several facing cuts to get the desired<br />dimension and finish without breaking the tool<br /><ul><li>Two Rough Castings</li></li></ul><li>Advantage of Adaptive Control<br /><ul><li>Without Adaptive Control
  44. 44. Using Adaptive Control</li></li></ul><li>Time Increment Limits<br /><ul><li>Allows a series of limits to be programmed for a single tool
  45. 45. The switch to each set of limits occurs by specified time after the first call from the CNC
  46. 46. In the learn mode, each time segment learns a separate peak horsepower
  47. 47. Any number of segments can be used for each tool
  48. 48. An excellent solution for step drills and taps</li></li></ul><li>Time Increment Limits<br />Tap back to forward<br />Tap Reversing<br />Tap Cutting<br />
  49. 49. Advantages of Time Increment Limits<br /><ul><li>Tapping
  50. 50. Multiple holes with the same drill but varying material thicknesses
  51. 51. Deep hole drilling
  52. 52. Turning applications with variations in diameter
  53. 53. Contour milling
  54. 54. Step Drills</li></li></ul><li>Slope Monitoring<br /><ul><li>Slope monitoring
  55. 55. Allows horsepower limits based on the rate of change of a cut
  56. 56. Each slope can be set in the positive or negative direction
  57. 57. Using our time slice technology, the slope can change at any time during the cut</li></li></ul><li>How Slope Monitoring Works<br /><ul><li>The green line shows nominal cutting horsepower
  58. 58. The white line shows actual cutting horsepower
  59. 59. The red and yellow lines are the extreme and wear limits respectively
  60. 60. The Blue line is the under-cut limit</li></ul>8/6/2009<br />Caron Engineering TMS System7<br />24<br />
  61. 61. Using Slope and Normal<br />This example shows that using time slicing, normal monitoring and slope monitoring can be used during a cut<br />Normal<br />Monitoring<br />Slope<br />Monitoring<br />
  62. 62. Coolant Flow Monitoring<br /><ul><li>Up to (4) coolant flow/pressure sensors can be used.
  63. 63. The user sets the minimum flow/pressure allowed per tool
  64. 64. If the coolant flow/pressure drops below this level, an alarm is generated
  65. 65. All coolant flow/pressure is also graphed and can be reviewed with TMS Viewer
  66. 66. A variety of flow/pressure transducers are available depending on the maximum pressure and minimum flow rate to be monitored </li></li></ul><li>Coolant Flow 1<br />Coolant Flow 2<br />Coolant Flow 3<br />Coolant Flow 4<br />Coolant Flow 3 ALARM<br />
  67. 67. Data History<br /><ul><li>The 500 most recent events are saved and displayed
  68. 68. All monitoring data can be saved and later viewed with TMS Viewer
  69. 69. Event can also be logged to a file locally or on a network</li></li></ul><li>TMSViewer<br /><ul><li>Displays a stored file of collected tool monitor data
  70. 70. Excellent tool for analysis</li></li></ul><li>TMAC LiveView<br /><ul><li>Remote view of any TMAC system in the shop
  71. 71. Allows the user to create separate data files
  72. 72. You see what the operator sees</li></li></ul><li>Conclusion<br />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.<br />
  73. 73. Some TMAC7 Customers….<br /><ul><li>Smiths Aerospace
  74. 74. General Dynamics
  75. 75. Husky Injection Molding
  76. 76. Okuma America
  77. 77. Webster Valve
  78. 78. Orenda Aerospace
  79. 79. MTU Aero Engines
  80. 80. Rockwell International
  81. 81. Stryker HowmedicaOsteonics</li></ul>General Electric Aircraft<br />Smith & Wesson<br />Pratt & Whitney Aircraft<br />General Motors<br />Sikorsky Aircraft<br />Smith & Nephew<br />Melroe Bobcat<br />Arvin Meritor<br />Volvo Aerospace<br />NyproMold, Inc.<br />
  82. 82. To Contact Us<br />Caron Engineering Inc.<br />P.O. box 1529<br />1931 Sanford Road<br />Wells, ME 04090<br />(207) 646 6071<br /><br />Email:<br />