KOMET's BRINKHAUS ToolScope for automation in the machining industry independently monitors machine processes and can make adjustments for enhanced performance. It also features recording and storage capabilities, allowing for thorough analysis of machine runs and processes.
"Automation, while allowing for process improvements and increased precision in the machining industry, presents its own special set of needs," said a company spokesperson. "Chief among these is the need for enhanced process and machine tool monitoring. Such monitoring has the potential to reduce machine down time and scrap rates, improving manufacturing and consequent delivery times to customers. The BRINKHAUS ToolScope from KOMET features the latest technologies in process and machine tool monitoring in one package, providing customers with the knowledge and confidence that their operations will be optimal and safe."
The ToolScope connects directly to the CNC machine, detecting, recording and analyzing data from machine runs to find the peak running parameters for machining operations. "Using the same concepts behind other recording devices, the ToolScope is proven and is held to high standards, such as GE AE standard P11TF12," said the spokesperson. "Customers benefit from informative indicators, automatic configuration and a memory capacity of one to 10 months (dependent upon the rate of sensor data)."
With its Statistical Process Control (SPC) module, the ToolScope can quickly learn from a process, identifying the optimum tolerance bands. These tight tolerance bands can then be adjusted to the production process. Even slight production variations or disturbances in a process, such as cavities in a material, can be detected well in advance of tool breakage. The SPC is entirely self-taught, requiring no manual adjustment, and can be run in conjunction with a process control system.
ToolScope features an intelligent dynamic monitoring module that can determine the calibration of tolerance limits from the ingate, within the first 30 seconds of a process. As with the SPC, the dynamic monitoring module requires no manual adjustments. Calibration of the dynamic monitoring module is achieved in either of two ways: preliminary calibration or process calibration. In preliminary calibration, the interactions between a tool and a particular material are taught once. In process calibration, the first few seconds of a run are used as calibration criteria. According to the company, increasing tool wear does not present a problem for calibration.
The ToolScope can also be used to actively adjust and optimize processes. With the advanced Adaptive Control (AC) module, process variables are controlled by adjusting the process speed. The AC module will reduce the speed of tools that are overused, and increase the speed of tools that are underused or when air cuts are detected. Control can also be targeted to specific events, such as the detection of swarf jamming during drilling or of chatter vibration. In the case of special applications, manual regulation is also possible.
The ToolScope will save internal and external sensor data as a process log, and can store this information in memory for one to 10 months. Documentation of process logs and graphs is automatic, and can be stored in the common png, xls, or pdf formats. The oscilloscope function allows online visualization of the process in real time. These features afford complete process transparency and the review of faults that have occurred in previous runs, even those from months ago.
"One of the most appreciable features of the ToolScope is the ease with which it is implemented," said the spokesperson. "A KOMET BRINKHAUS technician will carry out the installation and commissioning of the device, and total machine downtime is only three to six hours. The system is subject to ongoing improvement and development, and users will continue to benefit from new innovations. BRINKHAUS support is always available via phone, remote connection or on site."
For more information contact:
KOMET of America, Inc.
2050 Mitchell Blvd.
Schaumburg, IL 60193
847-923-8400
customerservice.us@kometgroup.com
www.komet.com