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Real-Time Machine Shop Productivity & Optimization Solutions

Real-Time Machine Shop Productivity & Optimization Solutions. Vibration Control Monitor (VCM). VCM continuously monitors machine tool vibrations during machining

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Real-Time Machine Shop Productivity & Optimization Solutions

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  1. Real-Time Machine Shop Productivity & Optimization Solutions

  2. Vibration Control Monitor (VCM) • VCM continuously monitors machine tool vibrations during machining • VCM analyzes the vibration data in real-time and issues warnings and/or stops the machine if unacceptable vibration conditions occur – thereby preventing pending failures • VCM provides information about potential failures and can call for preventive action based on the machine’s vibration signature analysis

  3. VCM Main Features • Machine Vibration Signature Analysis • Simultaneous Monitoring of up to 3 Machine Components • Vibration Data Collection, Storage And Visualization • Lifetime Utilization Histogram Representing Machine Condition History • "Black Box" Post-Failure Vibration Analysis • Tool-Specific Vibration Monitoring • Tool & Part Run Out Detection • Fast Response Collision Detection

  4. VCM in Machine Environment

  5. VCM Configuration • Accelerometer(s) installed on vibration-prone machine location(s) • VCM Data Acquisition Hardware • VCM HMI can be integrated into: • Stand-alone PC • Siemens Sinumerik 840D • OKUMA OSP-P200

  6. Overall Machine Vibration Monitoring VCM can continuously monitor the “Overall” machine, guarding against excessive vibrations in every machining operation in two ways: Time-domain - VCM continuously measures a broadband of vibration acceleration, velocity, and displacement - according to the ISO 10816 standard. Frequency‑domain - VCM triggers alerts or alarms if the vibration exceeds its permissible band limits across the frequency spectrum

  7. Time-Domain Vibration Analysis • VCM analyzes the vibrations in Time-domain in three configurable frequency ranges: • Low frequency band - with adjustable bandwidth, to determine the vibration displacement level (peak to peak) within this band. • Medium frequency band - with adjustable bandwidth, to determine the vibration velocity level (RMS) within this band. • High frequency band - with adjustable bandwidth to determine the vibration acceleration level (RMS) in this band.

  8. Frequency-Domain Vibration Analysis • VCM uses Fast Fourier Transform (FFT) processing for: • Real-time frequency-domain analysis • Vibration signature recording and analysis In real-time frequency-domain analysis, VCM can analyze up to 10 configurable narrow bands. The bands may be selected based upon operating conditions and expected fault vibration characteristics.

  9. Tool-Specific Vibration Monitoring By distinguishing between vibration behaviors of various tools, VCM can automaticallyprevent dangerous vibration conditions for each tool. Tool-specific vibration monitoring is carried out in both time and frequency domains. Time‑domain analysis determines the overall vibration velocity level only within the medium frequency band.

  10. Tool-Specific Vibration Monitoring Setup

  11. Vibration Signature Analysis VCM enables preventive action to be taken based on a comparison of: • Machine’s current vibration signature • Machine’s “reference” vibration signature in healthy condition The deviation is limited by an envelope around machine’s reference signature.

  12. V-Signature Recording & Storage Direct NC program access to V‑Signature recording function. Start command initiates the recording process. It is forced to stop either by achieving required accuracy or by the Stop command. A V-Signature file is generated and saved automatically.

  13. VCM’s Collision Detection VCM interprets extreme vibration accelerations as collision of machine components (spindle, tool, machine table) and performs an emergency stop - preventing further damage

  14. Spindle Lifetime Histogram VCM continuously captures the spindle’s load, speed, vibration, and other factors affecting its condition over its lifetime and combines them into a single usage factor reflecting the true condition of the spindle.

  15. Post-Failure Vibration Analysis As a "Black Box", VCM stores machine vibration history for post-failure vibration analysis. VCM helps in: • Reporting on machine alarms • Discovering incorrect operating practices • Minimizing machine warranty costs • Communicating vibration and alarm information through a factory network

  16. VCM’s Competitive Advantages • PC-based User Interfacefully integrated into leading CNCs • Simple user interface requires minimum operator effort to run a new part • Universal solution applicable to any CNC control – new and old • Tool-specific monitoring enables protection of individual tools • VCM can operate for each tool

  17. VCM’s Competitive Advantages • VCM eliminates chatter (vibrations) - thus preventing damage to spindle, tools and parts • VCM can operate in a network under OMATIVE-Pro Production Performance Monitoring that enables comprehensive & reliable machine monitoring and supervision • Continuous vibration monitoring for a whole range of processes, incl. Milling, Drilling, Turning, Grinding, Broaching & Gear Hobbing.

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