XYNDATA: Improving Efficiency By Changing The World Of CNC Mach

• Posted by Joy Green May 24, 2022 Filed in Technology #CNC monitoring software  #CNC machine monitoring software  88 views
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  With the imminent implementation of new communication technologies in manufacturing processes, there is a lot of talk about data collection and monitoring. But, what is tool monitoring? You have probably heard of machine condition monitoring, which is a practice that evaluates the condition of the machining equipment over a period of time. By collecting operating data, these variables can be used to determine future performance and optimize maintenance, replacement of defective or worn parts and reduction of equipment downtime.

   

  

   

  But what is tool monitoring? The tools themselves are precise, hardened metal tools that perform the cutting, drilling or milling of a part. Tool monitoring is an extension of the concept of machine condition monitoring, as it aims to include tools with accurate analysis in order to monitor tool life and predict failures to improve manufacturing quality and reduce costs.

  Here is how these systems work and how they can be a key ally in industrial machining.

   

  What is a tool monitoring system?

   

  CNC machine tool monitoring seeks to harness data from the CNC machine to detect and predict the condition and life cycle of the tool. The more accurate the prediction of tool failure, the lower the overall cost of the tool by reducing failures and scrap and reducing unplanned downtime of the equipment.

  To monitor the tool, several factors are measured, including Machine Electrical Power Consumption, Torque, Acoustic Emission, Vibration, and Ultrasound, among other sensors used.

  The data collected is integrated through CNC monitoring software that can inform operators of tool wear and expected tool life. This provides greater visibility into the process and maximizes the service life of each tool. Predicting tool failure allows operators to replace tools at the optimum time, avoiding damage to the machine and the part being produced, and reducing scrap and tooling costs.

   

  How do tool monitoring systems work?

   

  All companies that work with machine tools must manage their tool life, whether consciously or not. Essentially we can talk about 3 approaches to the way tools are monitored. Each offers a varying degree of certainty in terms of indicating when tool failure will occur and as a result, each step offers varying degrees of effectiveness.

   

  1. Tool life averaging

   

  The first type of tool monitoring is basic and has a great deal of use in the machining industry, although it is not the most convenient. It consists of letting the tool run until failure as if only reactive maintenance were being performed on the equipment. When a tool fails, usage data is taken and average tool life is statistically calculated and used as a guiding parameter for tool replacement. Today, much of the machining industry carries out this practice, which, while simple to perform, has serious drawbacks.

  The reference point for averaging can be arbitrary as this method does not take into account possible variations due to the use of different materials in the machine. If the tool is replaced before the setpoint, tool life is wasted and tool labor costs increase, while if the tool fails before replacement, the tool's work is interrupted and scrap parts are generated, increasing overall costs.

   

  2. Tool monitoring and machine condition monitoring system

   

  This system analyses the power being used by the machine tool spindle and analyses the waveform to predict failure points. By reading the power amplitude over time, increases and decreases in load can indicate the proximity of a failure point. It is important to have reliable software to collect these variations and inform the operator.

  This system also has drawbacks, as the indications it gives can only capture the state of the tool at or very close to the point of failure. This means that the system is left vulnerable to potentially higher scrap rates, plus additional downtime and possible machine damage, depending on the type of failure.

   

  3. Integral tool monitoring

   

  The most advanced solution available, this approach to tool monitoring uses algorithms that can detect an approaching failure in time to replace the part within an acceptable maintenance shutdown and with a significant reduction in scrap. These systems use advanced algorithms to diagnose, predict and prevent failures and do not require sensors to monitor the tool, as they use high-frequency torque usage data to track tool performance.

   

  Key advantages of integrated tool monitoring

   

  An advanced tool monitoring system provides many benefits to the manufacturer, including:

   

  ➢ Accurate tool life: Tools can be optimized for specific jobs, depending on the type of machine, environment, or material.
  ➢ Extended tool life cycle: With tool condition monitoring, the tool life cycle is maximized by avoiding replacing tools too early or too late.
  ➢ CNC machine tool machine monitoring: Operators are notified of broken or worn tools, preventing damage to parts or machines.
  ➢ Improved quality: by detecting tool wear and breakage early, scrap, rework, out-of-tolerance, and out-of-specification parts are reduced.
  ➢ Predictive maintenance: tool failures can be accurately predicted and alerted in advance to manage predictive maintenance of equipment, avoiding unexpected failures and downtime.

   

  If you are looking to improve the monitoring of your CNC equipment and increase your overall machining efficiency, xyndata offers CNC machine monitoring software that collects data directly from the source - the CNC machine itself. To find out how Xyndata can fit your tool monitoring needs, feel free to contact their team today.