預防批量不(bù)良，降低(dī)産品缺陷風(fēn±¶g)險
通(tōng)過設置刀(dāo)具的(de)★♥×磨損極限，實時(shí)監測刀(dāo)具的(de)磨損狀态，當刀(dā≈<o)具的(de)磨損到(dào)達極限時(shí)，及≥γ©<時(shí)給出換刀(dāo)信号，避免∏< λ因為(wèi)刀(dāo)具提前失效而導緻的(de)零件(j♥®iàn)批量性缺陷。
By setting an upper side bounda£↕"ry for signals of to₹ol wear and
monitoring §₹λtool status, the system✔↑ will release a signal to tell custo↕$mers the
best timing to chang§>λ∑e tools when tools have reache✔✘βd their limits,which c☆<an
avoid massive defects iγπ<×n volume production caused by unex&¥"®pected faster tool
wear.
為(wèi)刀(dāo)具性能(néng)評估提供決策依據
通(tōng)過刀(dāo)具磨損監控系統采集到(>§ dào)的(de)實時(shí)加工(gōng)數(shù)據進行(xín←↕λg)對(duì)比分(fēn)析，可(kě)以評價 &↓↓刀(dāo)具的(de)性能(néng)。
The
system can compare historical←÷×♣ tool wear data to provide evi₩₩•dences for
decision-making of tool×σ performance evaluations.
消空(kōng)程／防碰撞系統
Gap Eliminator
(GE)
消空(kōng)程／防碰撞是(shì)一( ©yī)套能(néng)夠縮短(duǎn)ε§♣磨削過程中的(de)空(kōng)程時(shí)間(jiān γ)，并避免砂輪和(hé)工(gōng)件(jià≤$§n)發生(shēng)碰撞的(de)智能(néng)控制(zhì)系統。
适用(yòng)範圍：各類磨削應用(yòng)
Gap Eliminator is a package of in↑π≠telligent control system ÷€×≥that
shorten free st∏∑roke time in grinding processes ★<↕and avoid severe impact o♣±r
collisions between gr♣±βinding wheel and workp≥✘™₹ieces at the same time.
Applicable fields:all kinds of ∑grinding applications
效率提升
原實際加工(gōng)時(shí)間(jiān)為(wèi)38s，使用(yòng)消空(kōng)程／防碰撞系統後節拍(pāβ↑i)降低(dī)到(dào)32s，節省6s，效率提升15％左右。
Original
cycle time was 38 sec←σ.When GE systen was instalγ εled,cycletime was re✘ duoedto 32
seo, so ₹€the efficiency was improved about ←₹Ω✘15%
防碰撞
原來(lái)無碰撞保護，導緻主軸撞壞設備維修，使用Ω≠±(yòng)防碰撞系統後，軟件(jiàn)自(zì)動識别反饋，發∏↕出控制(zhì)信号給機(jī)床，機(jī)床複位并發出報(bào)警信号↕γ♣。
After
GE system was install≥★ed,software automatically recognizedδε prercoll ision
signals,and then gaveφ♠ comundsto machine.Grindin€≤✘&g machine fed back and released
aα¥€✘larm at the end.
提升磨削效率
在磨削過程中，消空(kōng)程／防碰撞系α←λ¶統通(tōng)過砂輪接觸工(gōng)件(jiàn)所産生(sh≥¥•™ēng)的(de)信号變化(huà)，來(lái)有(yǒu)效提示機(j' ≤∏ī)床切換移動速度，降低(dī)空(kōng)程占用(yò₹ <ng)的(de)時(shí)間(jiān)，使♣Ω>β加工(gōng)效率大(dà)幅提升。
In grinding processe★↓>s, GE system controls machine' $↕sfeeding speed
in accord ♥¥ance with signals from the contact σσbetween wheel and workpieces δ₩↓§in
order to reduce the time of free ≥γσstroke and raise the efficiency ≥§up.
有(yǒu)效控制(zhì)因來(lái)料尺寸異常所造成的(d <↓ e)碰撞及品質風(fēng)險
由于來(lái)料異常，會(huì)導緻異常零件(jiàn)在快(ku><>ài)進階段與砂輪發生(shēng)劇(jù)烈碰撞，對(duì)砂輪、Ω>主軸和(hé)夾具都(dōu)會(huì)産生(•×shēng)損壞，消空(kōng)程／防碰撞系統可(kě)以對(δλ$<duì)此類情況進行(xíng)有(yǒu)效的(de)監控，₹↔©當異常發生(shēng)時(shí)，及時(shí)發出報(bào ¶®∑)警給機(jī)床進行(xíng)停機(jī)，降低(dī)因碰撞帶來→≈→(lái)的(de)各種損傷。
It
is possible for grinding whee↓♥₹l to have severe colα≤δlision with abnormal parβ→↑ts
when approaching,due to uncertaα♠£inty of in-coming parts,☆γ÷which could destroy
grindin∞♣&g wheel,fixture even spindle.Th♣↑$erefore, GE is invented to monitor suc®'h
situation.When collisio↕₽n is going to happen,GE releases alar' m immediately to
stop machines and to ∏•≠prevent collision and followiβ ng damage.
自(zì)适應加工(gōng)系統（功率版）
Adaptive Machining-Power(AM-P)
自(zì)适應加工(gōng)（功率版）是(shì)一(y←≈ī)套能(néng)夠實時(shí)測量主α 軸負載，同時(shí)調節進給倍率以提高(gāo)加Ω"©工(gōng)效率的(de)智能(néng)控制(zhì)系統。
适用(yòng)範圍：單件(jiàn)／批量加工(gōng)££•∏、半精加工(gōng)、粗加工(gōng)（攻絲♦÷÷¶、恒線速車(chē)削除外(wài)）
Adaptive
Machining -Powe¥÷r(AM-P) is a packege of intel• ligent control system that measu☆≠✘re
spindle load and ad₽₹just feed rate simulta₩±neously to achieve higher machi ≥↔ning
efficiency.Applic<☆able fields:Single/ma♥♦'ss production,semi-finishingβδ,roughing
(except tapping and ₹ $γturning with constant linear speed)
效率提升
原實際加工(gōng)段平均時(shí)©♦✔✔間(jiān)為(wèi)91秒(miǎo)，使用(yòng)“自(zì)适應加工(gōng)系統”後節拍(pāi)降低(dī)到(dào)77秒(miǎo)，效率提升15.4％。
Original
cycle time was 91 se'★Ω↔c. After AM-P was appl ied σ↕ on the machine. the cycle time
was reγ¥♦♥duced to 77 sec,whose ≤©®$efficiency was raised by 15✔ .4
刀(dāo)具過載保護
由于來(lái)料異常，導緻切削量異常增加，使₹∞得(de)刀(dāo)具負載超過設定上(shànε g)限，系統及時(shí)輸出報(bào)警至α©機(jī)床，加工(gōng)暫停。
Because of
unusual stoσ¥>ck removed,power signal showed that§←☆✘ spindle load wes out of limit at the begiδ≤∏λming Thus,AMH-P contro₹≥✘πl led the
machine to stop ↔∏δand release alarm imediately.
提升加工(gōng)效率
數(shù)控機(jī)床在加工(gōng)時(s>☆δhí)，會(huì)根據程序中給定的(de)進給速度進行(xíσ÷∞$ng)切削。切削過程中，加工(gōng)外(wài)部條件(j≈λiàn)是(shì)會(huì)發生(shēng)β←變化(huà)的(de)，而設備卻不(bù)能(né₽↔↓ng)夠對(duì)随時(shí)變化(huà)的(de)加工(g♥÷ōng)條件(jiàn)做(zuò)出相(x₹πiàng)應的(de)調整。自(zì)适應加工(gōng)（功率版）通(tσ₩Ωōng)過實時(shí)測量主軸功率，利用(yòng)自(zì)适應算(suà↓♣↕®n)法最快(kuài)地(dì)計(jì)≈$'λ算(suàn)出合理(lǐ)的(de)進給速度，并及時>•α(shí)調整進給倍率，負載小(xiǎo)的(de)工(gōng)況£，增大(dà)進給速度：負載大(dà)的(♣££de)工(gōng)況，減小(xiǎo)進給速度，達到(γ≈✔≠dào)恒功率切削的(de)目的(de)。
When machine is work♣£✔ing, it cuts under certain feed ¶β★↕rate according
to program.During ¥→•cutting process,cutting condition is c<∏★±hanging time to time,
but machin€↔§e can not feedback and a×←djust properly based on tha∑ €t.Therefore,based
on power signal aδ∑★σnd our adaptive algo↓★∏®rithm,AM-P is designed to ↔£Ω®calculate proper
feed andε∞ adjust feed rate in the shortes÷¶t time. In order to reach δ♥a
constant-power macφ©®hining, AM-P will increas&→e feed rate if power is lower tha↕δ∞®n
its standard and vice versa.
刀(dāo)具過載保護
加工(gōng)負載過大(dà)會(huì)導緻加工(gōng)過程中出現(®÷xiàn)“悶刀(dāo)”現(xiàn)象，自(zì)适應加工(gō®δng)（功率版）對(duì)每把刀(dāo)具自(zì)動計₹✘♠≥(jì)算(suàn)負載上(shàng)限，當功率超過上(shànΩ∑©g)限時(shí)，輸出報(bào)警，達到(dào)保護刀(dāo)具α←和(hé)機(jī)床的(de)目的(de)。
Cutting
tools could be jammed when t¥÷ε₹he when the cutting force≤©± is over load. To avoid
<♥✘ this situation, AM-P ≥λσ<automatically calculates an↓£ upper limit of power for each
cuttin£ g tool.When tools are overl₩ ₽εoaded, it will output ala¥®±rm to protect tools
and sto•>p the machine.
機(jī)床熱(rè)誤差補償系統
Machine
Tool Thermal Error Comp$©>✔ensation(MTEC)
機(jī)床熱(rè)誤差補償系統基于機(jī)<€床各軸溫度變化(huà)，建立對(duì)應的(de)Ω"熱(rè)誤差補償模型，能(néng)根據其對(duì)各軸進π∑™行(xíng)實時(shí)補償，以保證機(jī)床的(de)高(gāo)加工∏₽(gōng)精度和(hé)批量穩定性。
适用(yòng)範圍：各類機(jī)床
The MTEC is used to bu→πild up the thermal error compensatio≈←n model
based on the temperature$•≥ of each machine tool axis,and can c↓$ompensate the
machining accuracy a∏ ←nd product stability.
Application fields:All types of macσ✘€hine tools
主軸熱(rè)補償
補償前後，主軸的(de)最大(dà)熱(rè)誤差減少(shǎo)Ω 約71％，補償效果良好(hǎo)。
After MTEC applicati ₹•on,the
spindle therm<€☆al
error is compensated by 7→®&1% with very good effect.
進給軸熱(rè)補償
補償前後，X軸進給軸的(de)最大(dà)熱(rè)誤差減少→∏(shǎo)約80％，補償效果良好(hǎo)。
After MTEC application thφ§© e spindle thermal,error is compensate¥φ±d by
80% with very good effec≥≠t.
提高(gāo)加工(gōng)精度和(hé)批量穩定性
工(gōng)件(jiàn)加工(gōng)過程中，機(jī)床各軸産生♣≥(shēng)的(de)熱(rè)誤差可(kě)能ε≤¶(néng)會(huì)導緻工(gōng)件(jiàn)尺寸♥π波動大(dà)，甚至超差産生(shēng)不(bù)良品。機(jī©ε₹)床熱(rè)誤差補償系統通(tōng)過¶₩δ實時(shí)補償各軸熱(rè)誤差，提高(gāo)了(l>&÷e)加工(gōng)精度和(hé)批量穩定性。
When machining a part,thermal err↓∏or can cause large fluctuation of
λ♦
dimension,and even lead to defective p"↑♠♣roducts. MTEC is able to i₹>γmprove
machining preciε®sion and batch stability by compensat↕Ωing the thermal error in→♠
real time.
降低(dī)熱(rè)機(jī)時(shí←≤)間(jiān)
正常加工(gōng)前，機(jī)床通(tōng)常需±∑要(yào)較長(cháng)時(shí)間₽<✘ (jiān)來(lái)熱(rè)機(jī)至熱(rè)✘♦穩态，才能(néng)保證産品加工(gōng)質量✘☆。機(jī)床熱(rè)誤差補償系統避免了(le)長(cháng)時(shí₽"₩∏)間(jiān)的(de)熱(rè)機(jī)過程，從(cóng)而達到(d<$∏ào)降低(dī)時(shí)間(jiān)成本和(hé)能(néσ ♦ng)耗的(de)效果。
Before
machining a part,t☆♦↕he machine tool usually needs long ti×±me to warm up to reach a
thermal e¥♠quilibrium state, so that the¥↕←← product quality can be ensured.MTEC ca>♦•±n
help to avoid this long ≥'∏period of warm-up process and dec&♠rease time cost and
energy consu☆ ☆®mption.
降低(dī)機(jī)床使用(yòng)環境要(yào)求
環境溫度的(de)變化(huà)可(kě)能(néng)也(yě)會(&©σσhuì)導緻熱(rè)誤差的(de)産生(shēng) →&♦，在溫差大(dà)的(de)地(dì)方尤其明(mγ∑$íng)顯，為(wèi)了(le)保證加工(☆¥ ÷gōng)精度，甚至可(kě)能(néng∞©₹δ)需要(yào)使用(yòng)恒溫車(chē)間(jΩ₹' iān)。使用(yòng)機(jī)床熱(rè)誤差補償✘≠系統大(dà)大(dà)降低(dī)了(le)£'環境溫度的(de)影(yǐng)響，不(> ¥bù)需要(yào)恒溫車(chē)間(jiān)也(yě)能(néng)達™↕→∏到(dào)較高(gāo)的(de)加工(gōng)§β♥精度，從(cóng)而達到(dào)降低(dī)基建成本的(de)效果。
Environment
temperature changes can¶→ ± also lead to thermal erro& r,especially in those places
☆φ₩λ
with large temperature difference.In >¶₩÷order to ensured the machining
preci↕×←©sion,constant temperature wor→εkshops may even be neede≤™™d.Using MTEC system
can re←✔ duce influence of environment temperat↑♠αure a lot. The machine tool users
§ ₩↔can keep high precision without work₹"₽ing in a constant temperature workshopφ ↔✔.so
the construction cost can b≥₽$e reduced as result.
碰撞緩沖系統
Collision Buffer (CB)
當主軸／刀(dāo)柄／刀(dāo)具和(h饩γ)工(gōng)件(jiàn)／夾具發生(shēng)突然的(de)•€☆ 碰撞時(shí)，碰撞緩沖系統會(huì)♦§'自(zì)動感知(zhī)碰撞信号，快(kuài)速地(dì)發出↔ε→報(bào)警信号給機(jī)床做(zuò)急停，避免主軸因☆★意外(wài)碰撞而損壞。适用(yòng)範圍：所有(y×↑ǒu)類型機(jī)床、機(jī)械手
When spindle/tool shank/tool body ≥$σ collides with workpiece/fixture.
<
CB system detects the collision signal€♠s automatically. and releas™±¶es alarm to
stop machi'δ↓↓nes rapidly,avoiding the catastro₽ €phic damage on spindle. Application fields:machine Ω tool and robot
響應速度快(kuài)
當發生(shēng)碰撞時(shí)，CB系統能(néng)在3毫秒(miǎo)內(nèi)快(kuài)速響應，輸出信号給機(∑ ©≤jī)床停機(jī)
When the
collision was h×≈∏appened,the CB system w✔↓ill respond quickly withi✔∑n 3 milliseconds
and output a s÷↕™ignal to stop the machine.
安全性高(gāo)
撞機(jī)發生(shēng)後，CB系統最大(dà)可(kě)能(néng)的(de)保護主軸不(b™✔©×ù)受傷害
After the
collision,the CB system can>→©© protect the spindle from d'♥amage as safe as pos" sible.
撞機(jī)前後--主軸靜(jìng)态精度測量結果
Before and after--Comparison
of s₩≠&pindle static precisio→✘εn measurement resultsλ Ω₩
撞機(jī)前後--主軸動态精度測量結果
Before and after--Comparison
®<>of spindle dynamic precision mαπeasurement results
預測性維護系統
Predictive Maintenance(PM)
預測性維護系統是(shì)監控設備關鍵或"α<≈易故障部件(jiàn)老(lǎo)化(huà)故障的(de≈↓)智能(néng)監控系統。該系統通(tōng)過對(du✔&∏ì)設備熱(rè)機(jī)或空(kōng)轉•↔"∏過程中的(de)多(duō)源信号進行(xí→→₹£ng)分(fēn)析，提取設備部件(jiàn)的(de)預維特征，實現(xià₽↓φ≥n)長(cháng)期監控設備老(lǎo)化(huà)&γ故障趨勢并預警的(de)功能(néng)。
适用(yòng)範圍：機(jī)床主軸、進給軸傳動部件(jiàn)。
Predictive
maintenance(PM) is an intλ÷Ω♠elligent system that monitors im<☆portant components an→®$σd
those with short mean time between ±'failure.
This
product is able $'&to extract PM features of compon≤♦∏×ents from multiple signalsλ€λ
during the heating-up or idle p↔♦ €rocesses to monitor ≥<γagingtendency of those
©♥components and to warn custoδ mers when features are beyondφ↕ their thresholds.
Applicable fields:Tr↑∑ansmission mechanism of sp> δindle and feeding.
系統架構
System Architecture
硬件(jiàn)包含：傳感器(qì)及采集闆卡，邊緣計(jì★γ♣✘)算(suàn)終端
軟件(jiàn)包含：底層預維軟件(j✘§iàn)，上(shàng)位預維查看(kàn)軟件(jiàn)
Hardware:Sensors,Data
Acqu∏isition boards and IPSoftware:PM ♣β₽ lower computation software &amλ∞€λp; PM upper
monitoring software
系統操作(zuò)簡單，評價準确快(kuài)捷
客戶能(néng)自(zì)由決定檢查周期，定期執行(xíng)1～2分(fēn)鐘(zhōng)的(de)程序就(jiù)能(néng)得(de)§δ≈↔知(zhī)設備健康狀況。
Customers are free to decγ& ₹ide evaluation period and to execut≈γα∏e a
2-minite program und≈×'er this period to know health
status of£© equipment.
适用(yòng)于各種場(chǎng)景，同¥★時(shí)擴展性高(gāo)
除了(le)适合于标準設備的(de)主軸和(hé)進給軸，産品可(kě)以根∑™據定制(zhì)需求拓展至其他(tā)設備部件(jiσ∑¶∞àn)。
Except for usual spindle and® feeding axis,PM can be applied÷ "♠ on
other components according to cuπ stomers' demand.
案例展示：某知(zhī)名品牌發動機(jī)缸體(tǐ)加工(£×gōng)現(xiàn)場(chǎng)，共24台卧式加工(gōng)中心；為(wèi)其構建針對(duì)主軸和(h↕é)進給軸的(de)預測性維護系統。
Case study:we deployed ±&PM system on 24 horizontal m ₩ achine centers
in a engine pl✘↔ant of a big brand.
價值呈現(xiàn)
Key value
價值1：在2020年(nián)6月(yuè)發現(xiàn)編号為(wèi)005号機(jī)床主軸預維特征值達到(dào)預®警線，在2020年(nián)7月(yuè)預維特征值達到(dào)報(bào)警λα×線。設備維護部門(mén)于10月(yuè)假期期間(jiān)進行(xíng)了(le)主軸φ£∞更換，預維特征值降至合理(lǐ)範圍。同時(sh λí)換下(xià)來(lái)的(de)主軸經過生(shēng)★±産廠(chǎng)家(jiā)确認，已無維修價值，需報(b&δào)廢處理(lǐ)。
1st Value: In
June 2020, the vibratio≤☆≈n characters of spindle o→∏®f #005 machine center achi¶"eved
early warning line on α✘. After one month. it went beyond the ∞ε✘warning line.With
double cheπ♦ck from maintenance d±ε♠πepartment,engineers repl>≤aced that spindle in
Octob☆→er.After that,the vibration characters ★÷returned to normal
value.Fi≥'nally.OEM confirmed that™σ' the ball bearing of that s↑± pindle were severe
wear and∞λ↔ there was no need to repair.
價值2：在對(duì)比排查24台設備進給軸預維特征值後，發現(xiàn)編号第8、12、16、22号設備的(de)預維特征數(shù)據同比較高(gāo)，在設備維護部門(méΩγn)定期保養後發現(xiàn)進給軸出現(xiàn)了(l∑&e)不(bù)同狀況的(de)故障。
2nd value:with the comφ₹₩'parison of vibration ch$'•aracters of feeding
axis amo®© ng 24 centers, customer≈'¥π found that #8,12.16 a&↔₽¥nd 22 centers had obvious
higher ∞ value.After regular maintenance,t ←&♦hese 4 centers had visible wear and
r ®αust on ball screw.
24台設備橫向對(duì)比
Comparison
of 24 machine centeδ≤rs
對(duì)應4個(gè)異常數(shù)據的(de)鏽蝕和(hé)'₹γ磨損檢查結果
Maintenance results of 4 abnormal
d§≥♣πata