ACM Adaptive Control and Monitoring

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1 ACM Adaptive Control and Monitoring The only metal cutting optimization system that can save up to 40% on machining operations resulting from: Cycle time savings Tool life extension Increased machine availability Increased productivity Reduced machining costs Consistently high workpiece quality Machine & CNC: Hitachi Seiki with Fanuc 15M Material: Medium Steel Part Description: Turbine blades Minutes mm/min mm With ACM: Without ACM: Time Savings: Special RPM = 160 Feed = 100 Dia. = % With ACM Without ACM Special RPM = 160 Feed = 100 Dia. = % Special Face Mill/Hss End Mill Carbide Ball Mill Face Mill/Hss End Mill Carbide Face Mill/Hss End Mill/Hss RPM = 150 RPM = 160 RPM = 700 RPM = 150 RPM = 180 RPM = 1900 RPM = 230 RPM = 400 Feed = 100 Feed = 50 Feed = 100 Feed = 1300 Feed = 55 Feed = 40 Feed = 45 Feed = 250 Dia. = 60 Dia. = 50 Dia. = 16 Dia. = 8 Dia. = 50 Dia. = 5 Dia. = 50 Dia. = % % % % % % % % mm/min mm Total 9.47 Minutes Minutes 26.2% Overall Time Savings for Job: 26.2% Control feed rate Monitor tools Get reports on key machining parameters The ACM system adapts machining to your needs and your production goals. ACM can operate in two modes: Adaptive Control - ACM optimizes the programmed feed rate - speeding up cutting when the path is obstacle-free and slowing down when geometry, material hardness, or tool conditions demand caution. Monitoring - Tools, spindles, and parts are monitored for breakage, overload, missing tools, repeated runs of the same part, etc. Dangerous conditions are detected and corrected before damage occurs. The ACM system deals with the harmful effects of constantly changing and unpredictable cutting conditions, things the NC program cannot compansate for. Using ACM means more efficient machining!

2 ACM Reporting and Analytics Shopfloor managers benefit from the informative reports that ACM produces; they contain the data and insight needed to improve overall machining operations. Reports on machine and tool utilization, actual feed rate, time savings, tool wear, tool life, and more are available for each machine equipped with ACM. Status Report - [bfg1_5.mst: 21-Nov-12 16:31:29-17:14:19] Power Scale: 5% Period: 30 min. Resolution: 30 sec. Job: 1:1 Job: 1:1 Ref. No.: 1:1 (control) Ref. No.: 1:1 Alarm Overload Cutting Operation Spindle Offline 1:1 Load 2:1 100% [16:41:59] Feed 100% - Feed - Load - Torq.Y - Torq.X - Torq.Z Max.Load 1: 99.0 [time: 16:41:59] 16:35 16:40 16:45 16:50 16:55 17:00 Sample report: Machine utilization over a 30 minute production period ACM Use Promotes Sustainable Machining Reduces energy consumption due to shorter cycle times Reduces coolant use due to shorter cycle times Extends tool life, avoiding tool breakage and preserving tools for recycling Reduces metal waste due to extended tool life and fewer damaged workpieces Implementing ACM - All CNCs Can Benefit Virtually all new and old CNC machines can be equipped with ACM technology. Depending on the CNC type, different configurations are available. The ACM system's two main components are the HMI and the real-time control, which automatically performs monitoring and optimization functions. Sample screens from various CNCs

3 VCM Vibration Control Monitor The only system that successfully monitors machine vibration and avoids tool breakage and catastrophic collision-related damage VCM achieves vibration control through constant monitoring of machine tools and spindles. VCM detects collisions and prevents or minimizes damage. Always-On Condition Monitoring Machine tool and spindle are monitored continuously for vibration How VCM condition monitoring works With sensors placed in critical locations, realtime conditions are continuously monitored by the measurement of vibration acceleration, velocity, and displacement. Under high-risk vibration conditions, VCM stops the machine in order to prevent damage to the spindle and other machine parts. Automatic readings and comparisons to the machine's baseline vibration signature are routinely made. Significant deviations from the machine's baseline vibration signature trigger maintenance alerts. Process Control Tools are individually monitored for vibration How VCM process-control works Strategically-placed sensors enable accurate monitoring of each individual tool's vibrations in real time. When excessive vibration is detected, VCM stops the machine in order to prevent damage to the tool and machined part. Prevents collision-related damage With VCM installed, impending collisions involving the spindle, tool, or machine table are detected. In less than one millisecond, VCM detects the collision, and sends a signal to the machine to perform an emergency stop. Damage to the machine, spindle, and workpiece are kept to a minimum. OMATIVE VCM Chan1 Channel reset Auto \MPF.DIR TEST_RTP.MPF Program aborted Open ROV Save As... Spectral Analysis - [D:\OMATIVE_ACM\WGF5_C2.snv : 17-Feb-12 11:17:44] File Selection Frequency Band Selection Spindle Speed Filter Enabled Display Specified Band 1000 rpm From: 0 Hz To: 192 Hz Vavg. 1 mm/sec Settings Channel 1 Channel 2 - Vrms F Hz Add Bounded Reference Average Signature Reference Overlap Export XLS-File Open XLS-File Machine Tool Vibration Signature

4 VCM Benefits for Condition Monitoring and Process Control Prevents breakage Enables pre-emptive maintenance and repair work Avoids extended disruptions to productivity Avoids costly replacements of machine parts and tools due to breakage VCM Data Shopfloor managers easily keep track of the condition of machines, spindles, and tools, with VCM statistics and graphs easily accessible via the machine's HMI. The system records all vibration patterns and events, including breakage, crashes, failures, improper technical practices, and fixture problems. This information is used to help improve machining processes and to understand the machine's condition. In addition, technical or equipment problems can be immediately discovered and resolved. OMATIVE VCM Chan1 Channel reset Auto \MPF.DIR TEST_ADIN.MPF Program aborted Open ROV File Viewer - [D:\odb_vcm\Advanced\MON_3Slot_C1.msv : 17-Aug-12 13:53:30-13:55:17] Save As... Time Scale: 1 min NC Program: [no job] Resolution: 1 sec Ref. No.: Period: 100 ms NC Program: Ref. No.: 1:BevelCut 1:/1 Settings Alarm Arms Vrms Dpeak Operation Arms 2 m/sec^2 Vrms 2 mm/sec Dpeak 200 um [13:54:26] 17-Aug-12 13:54:26 NC-Prog: BevelCut Tool: Operation: [1, 1] Load: Speed: Arms:1.18 mm/sec^2 Vrms:1.33 mm/sec Scroll-> Scroll->> <-Scroll Dpeak: 101 um Alarms FM: 1* Alerts TM: Dpeak <<-Scroll 13:54:10 13:54:20 13:54:30 13:54:40 13:54:50 13:55:00 13:55:10 Show VCM Settings Export XLS-File Open XLS-File VCM Installation Example of excessive vibration triggering an alarm All machines can be equipped with the VCM in a smooth and speedy installation process. The VCM system consists of a Data Acquisition (DAQ) unit, vibration sensor(s), and Windows-based software that is integrated into the CNC. Each unit can support up to three channels. Ethernet LAN Data Transfer, Analysis, and Remote Storage VCM DAQ Unit Accelerometer Located Near Spindle

5 OMATIVE-Pro THE ULTIMATE SHOPFLOOR INFORMATION MANAGEMENT SYSTEM Connect OMATIVE-Pro to all the machine tools in your factory. Manage shopfloor operations through a comprehensive view of all of the parameters relevant to: Productivity Efficiency Planning Maintenance Costs OMATIVE-Pro extracts the crucial machine information your managers need to run tight operations. Real-time event data from machine tools continuously stream to OMATIVE-Pro, enabling managers to: Track job progress Estimate production output Record the number of parts produced in every batch per machine Analyze machining costs Record and analyze tool use and tooling costs Compare tool performance by manufacturer and suppliers Track and diagnose machine conditions and the source of problems Diagnose production bottlenecks and production control issues Identify machining and production disruptions, and analyze their causes Check NC program efficiency Optimize NC programs, tooling, fixturing, etc. 24-hour Production Control and Machine Condition Monitoring OMATIVE-Pro monitors production, machine condition, and performance in real time. This provides an objective measurement of machine and operator efficiency, and machine maintenance status. It provides statistics for all these parameters, and includes summaries of utilization, downtime, productivity, number of manufactured parts, machine condition, and more. OMATIVE-Pro - [Database: machineshop_1] Machines View Database Status Production Help Machine machine-1 Job 11:34 11:35 11:36 11:37 11:38 11:39 11:40 11:41 11:42 11:43 [running time] Jog MDI, Tool: T28_2 Machine Maintenance machine-2 W6-P234 00:00:53 Auto, Tool: D6 Operation 1 <00:00:05> machine-3 Jog MDI, Tool: N5_78 ACM Offline Machine Idle machine-4 Auto, Tool: Z8_45 ALARM 5: TOOL BROKEN! Operation 13 <00:02:27> machine-5 W34-P957 00:27:09 Auto, Tool: C5_a Part Loading machine-6 W38-P003 00:00:09 Auto, Tool: GT289 Operation 6 <00:00:08> machine-7 W33-P75 00:01:19 Auto, Tool: D17 Job 32 <00:01:19> Machine Off ACM Offline Idle Idle with Reason Job Running Spindle On Operation Cutting Overload Alarm Scale: 10min. Refresh: 1sec. Total machines: 7 Total connected: 7 17/02/11 11:37:45 OMATIVE-Pro production and diagnostic data analysis & presentation

6 Operational Intelligence OMATIVE-Pro stores production performance history in its database, so that shop managers benefit from a long and documented view of operations. Making decisions on how to optimize operations becomes simpler and more informed. These include: Estimating production time and cost Optimizing machine use in order to avoid bottlenecks Optimizing tool use Scheduling jobs for specific machines Scheduling pre-emptive maintenance OMATIVE-Pro produces easy-to-read graphs and charts, including these sample reports: Shift performance Shift Performance - [9-Jan-11 00:00-15-Jan-11 23:59] Overall Equipment Efficiency 100% 80% OEE Report - [17-Jan-11 00:00-17-Jan-11 23:59] 60% Running Running Running Machine Use OEE Report - [17-Jan-11 00:00-17-Jan-11 23:59] Machine machine-1 machine-2 Available Time Machine Off Time 6:58: % 0:00:00 0.0% 0:00:00 0.0% Idle Time 6:15: % 4:13: % 2:31: % Running Time Efficiency 40% 10:45: % 19:46: % 21:28:3820% 89.5% Idle Idle Idle Undefined 1.9% Machine Off 5.6% Operator Pause 8.4% 0:00:00 0:00:00 3:16:00 5:10:07 0.0% 0.0% 13.6% 21.5% 8:33:14 5:05:47 3:26:04 2:18: % 21.2% 14.3% 9.6% 15:26:45 18:54:12 17:17:55 16:31: % 78.8% 72.1% 68.8% Machine Off Shift-1 Machine Off Shift-2 Machine Off Shift-3 Close Machine Maintenance 6.0% Part Loading 3.7% Tool Preparation 11.2% Run Time 63.6% Close Close OMATIVE-Pro Configuration Workstation - 1 Remote Workstation Machine - 1 Machine - 2 Machine - 3 Computer Network Workstation - 2 Machine - 4 Machine - 5 Machine - 6 Server OMATIVE-Pro -- Getting the important information where it will do the most good!

7 OMATIVE-Pro Condition Monitoring for Predictive Maintenance OMATIVE-Pro monitors the condition of the machine tools on your shopfloor, which enables a predictive maintenance policy the key to productivity that achieves: Maximum machine uptime Minimum disruption to production schedules OMATIVE-Pro's expert system allows manufacturers to more precisely plan and schedule operations, conduct timely maintenance, and avoid unforeseen costs. Detection is Protection OMATIVE-Pro monitoring ensures that manufacturers maintain their machines in top condition. The real-time data measured and collected provide shopfloor managers with accurate information, the tools required for predictive maintenance. Location and status of vibration, load, and temperature sensors Benefits to Manufacturers, Machines, and Parts With OMATIVE-Pro's constant monitoring of the critical parameters of shopfloor machinery, there are many benefits for manufacturers that integrate the system into their regular operations: Increase productivity Real-time data enables more flexibility in planning and managing production Minimize disruptions to production Minimize unscheduled machine downtime Reduce costs Costly repairs are avoided when machines are well-maintained in a timely manner Longer life for machine tools Well-maintained machine tools last longer and work better Higher part quality Well-maintained machines produce higher quality parts, cut with greater precision

8 Opti-Green Advanced Green Machining System Opti-Green optimizes: Total energy consumed Peak energy consumption Coolant utilization Cost per part, including energy costs and cost of machine time Opti-Green utilizes real-time tool feed rate control and the monitoring of energy consumption at various machine components, including motors, pumps, air compressors, and more. Opti-Green can be integrated into any factory network. Working together with the optional OMATIVE-Pro Productivity Management system, you will see in real time the status of each machine, including: machine on/off status, the current job, operation, and tool, the current power consumption, an indication of actual material cutting, tool overload, and machine alarms. OMATIVE Opti-Green is a system aimed at effectively reducing energy consumption and environmentally damaging processes presently inherent in the manufacturing processes, while ensuring maximum production output. The O M AT I V E Opti-Green system may be integrated into any PC-based CNC, or standalone PC connected to any new or old CNC. For optimal environmental purposes and in pursuit of industrial energy conservation, adaptive machining is carried out in accordance with Energy Optimization as its main criterion. In the diagram, the areas under the two Power- Time charts represent the energy consumed during the machining of a part one with Standard CNC Machining and one with Adaptive Machining. The lower chart compares the Total Energy Consumed for the two machining processes. Significant energy as well as production time are saved per produced part when Adaptive Control machining techniques are applied according to Energy Optimization criteria. omative@omative.com OMATIVE Systems