DIGITAL PRODUCTIVITY SOLUTIONS

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1 DIGITAL PRODUCTIVITY SOLUTIONS Discover unique and profound KOMET Industry 4.0 solutions for your machining and your machinery

2 UNIQUE AND PROFOUND KOMET INDUSTRY 4.0 SOLUTIONS ToolScope, or how machines become smart With the field of digital productivity solutions, KOMET is setting the course for the digital future of machining. The ToolScope monitoring and assistance system provides the basis for this. With ToolScope, the KOMET GROUP is the only tool manufacturer to offer a true Industry 4.0 solution, even for small and medium-sized companies. It records and documents the machine's internal data during the machining process, such as the torque of a spindle or name of the current program. Occurrences such as tool changes or machine standstills are also recorded and are available for further analysis. ToolScopes can be integrated exceptionally well into customers' IT infrastructure. Machines which are equipped with ToolScopes can store their operating data in a cloud. The data can be called up in clear reports. Even if it is only installed on one machine, the investment pays off within a short time. "With our systems, we are directly at the machine with our customer. As a result, we learn of the challenges first-hand. Our developments are always related to concrete challenges in manufacturing, and therefore offer our customers a component that makes the value-added chain more efficient," says Dr Jan Brinkhaus, General Manager of KOMET BRINKHAUS GmbH. Big data solutions from ToolScope ToolScope now also available as software The monitoring and assistance system ToolScope has rapidly developed. Its traditional capabilities of recording and evaluating machine internal signals were massively extended. ToolScope now offers its services as a big data provider, too. KOMET delivers evaluation tools for the provided data. Assistance system ToolScope Apps ToolScope Net KOMET Cloud ToolScope Cockpit Hardware for machine tools Apps that can be licensed and activated Software for networking machines Cloud service for global networking and data storage Software for visualisation, monitoring for databases 2

3 KOMET BRINKHAUS TOOLSCOPE APPS In order to offer users added value, KOMET BRINKHAUS has developed a number of applications, known as apps, that are easy to license and activate. These allow users to easily access and utilize the recorded machine-, operating- and process-data. The focus was on operator convenience and modularity. TS-DataPro The TS-DataPro app is an efficient tool for collecting and generating data from the ToolScope. Possible analysis examples: Analysis of cycle time reduction Manufacturing time per component Energy consumption per process Spindle utilisation Spindle idling Downtime during the process Tool change duration Rework time during the process TS-PM app Tool/process monitoring TS-Wear app Wear monitoring TS-MDA app Automatic shift log TS-TCLog app Automatic tool change log TS-Cloud app Cloud database function TS-CM app Condition monitoring TS-AFC app Adaptive feed control CD-xDim app Collision detection TS-QRep app Quality monitoring/documentation 3

4 TOOLSCOPE FIRMWARE V.11 Assistance for machines and machinery With the new V.11 firmware, KOMET is marking a milestone in the digitisation of machine monitoring technology. KOMET breaks down traditional paradigms and offers unique new concepts. The new firmware can run on the ToolScope assistance system in the control cabinet, as well as on end customer network servers. In this way, the same ToolScope apps with the ToolScope Net software can be provided by a central server. KOMET has opened up its device interfaces for the introduction of V.11. Operation, data formats and remote access protocols are publicly accessible. All software components are available as free download. All KOMET apps got detail enhancements due to the new firmware, with noticeable advantages for the users. Detail enhancements on almost all software modules Improved connection to IT systems Improved tool data collection and tool data monitoring Improved breakage monitoring in series production processes Clever solutions for monitoring small batch sizes State-of-the-art data export of monitoring data Exemplary disclosure of data formats and interfaces The effect of monitoring parameters is directly visualised at the time of setting Monitoring processes are clearly displayed Clear displays (piece counter here) facilitate the understanding of processes in the machine Especially for machine manufacturers, the V.11 firmware offers improvements for the fieldbus interface (Profibus, Profinet, Modbus, etc.): Easy integration into your machines via standard PLC blocks enables rapid ToolScope integration Full ADAS compatibility (up to 14 axis data items) from the product standard Support for older Siemens NCUs (CPU314, CPU315) from the product standard Flexible switch between Intel and Motorola notation Modular, compressed interface enables full performance even with small fieldbus interfaces Easy commissioning thanks to displaying actual values on the fieldbus interface Test it now! For free trial access of V.11 firmware, simply register at for download. ToolScope data can be quickly visualised. KOMET even offers Excel templates to help you reach your goals faster. 4

5 TOOLSCOPE NET AND TOOLSCOPE CONNECTOR Your production becomes smart With the ToolScope Net software tool, KOMET offers the possibility of analysing machine data even without ToolScope hardware. ToolScope Net is installed quickly and easily into the existing server environment or on a laptop. The machine tools are connected to the local customer data network by equipping each individual machine with the ToolScope Connector software. Within the network, ToolScope Net then offers the functions of the KOMET apps as a network service. ToolScope communicates with machine operators on the machine via a dedicated user interface. ToolScope Net collects data from machines, such as motor currents, speed and axis positions. At the same time, the machine can be controlled automatically with ToolScope Net (for example: Spindle torque, alarm function and stop function of the machine). The software tools enable machine tools to be connected to a cloud and enable all required machine, process and operating data to be transferred. Easy means of digitising machinery Monitoring, process expertise, process documentation and transparency of processes in machines provided by a single system from a single source Process reliability and optimisation are ensured thanks to a range of individual apps to choose from Data output in CSV Saved measurement data and status information can be imported using Excel Intuitive operation Data reading on the machine and in the database Compatible with all common business and planning software solutions Test ToolScope Net! For free trial access, simply register at for download. 5

6 KOMET CLOUD Management of your machine data KOMET has developed the ideal cloud infrastructure for ToolScope. In order to use the cloud services, the use of V.11 firmware is required. The KOMET cloud can be rented via the Internet as a functional structure, or it can be installed as software for a local cloud in the customer's data centre. The data transfer via the Internet is encrypted. The KOMET servers are located in Germany and are under the control of a German company. The cloud software offers everything you need to manage large quantities of data. Machine status data is collected in databases and is available both in the database and in CSV format. The cloud transfers the data to the monitoring software, which visualises the data. The cloud provided by KOMET saves the user any effort related to setting up data storage. You can purchase efficient cloud units, including Cockpit software, directly from KOMET. KOMET provides free six month trial access to the cloud storage. Recording of all relevant machine data Data provision as SQL and CSV Networking of machines connected around the world Encrypted data transmission; server located in Germany Can be hosted locally at the customer's site Can be used immediately, free trial license Accessible worldwide via terminal devices 6

7 the plain presentation of all relevant data Machine Load Stand Still Time (78.18%) Operating Time (23.82%) The software collects the required data from the KOMET Cloud, analyses it and processes it to create plain presentations. This makes it possible to analyse, among others, machine standstill rates or the utilisation of machines with different NC programmes. It is possible to view data per machine, as well as configuring it for dashboard display. In Detail: Operating Time Unknown Reason (73.18%) Error Message By ToolScope (0.0%) Clear diagrams show what is happening in the production hall In Detail: Operating Time Monitored Production (0.35%) Non Monitored Production (0.0%) Rework (0.0%) Learn (0.8%) Export Image Data that can be visualised: Machine standstill times/machine operating times Allocation of machines with programs Proportions of tools on primary processing time Daily machine cycle Average, minimum and maximum tool life Distribution of tool changes throughout the day Frequency analyses of tool change reasons Central management, analysis and visualisation of machine data worldwide Transparency of machine processes Browse equipment data Analysis of non-networked machines is possible ("sneakernet") Seconds 0 Tool: Tool: Tool: Tool: Tool: Tool Days Seconds Hours Minutes Select Y-Axis: Seconds Tool service life diagrams provide information on potential savings Export Image Test it now! To access a free trial license for a local cloud for your server, simply register at for download Test the KOMET CLOUD! To access a free trial license for an Internet-based cloud structure, simply register at for download Percentage Monitored Production Non-Monitored Production Stand Still-Unknown Reason Stand Still-ToolScope Error Last week data for monitored, non monitored productions and stand still times Monitored Production Non-Monitored Production Stand Still-Unknown Reason Stand Still-ToolScope Error Bottleneck machines and idling machines can be identified quickly Test the Cockpit! To access a free trial license for a for your server, simply register at for download. 7

8 FEATURES AND REQUIREMENTS FOR KOMET CLOUD AND TOOLSCOPE NET ToolScope ToolScope Net (hardware installation) Installation Specifications requirements Controller hardware On the machine control panel Touchscreen Heidenhain Visualisation On the machine control panel Touchscreen KOMET Cloud Data handling Data storage Local On executing server On executing server Storage capacity Approx. 150 GB Limited only by harddisk size Unlimited Data export CSV, PDF, PNG, SQL CSV, PDF, PNG, SQL Remote data access FTP, SFTP, Windows According to IT approvals According to IT approvals Log files, process Statistics from Functions documentation from Apps TS-PM (only 840D sl) TS-AFC TS-Wear TS-TCLog TS-MDA TS-DataPro TS-QRep Displays Monitoring parameters per process Live sensor data, live monitoring view Live operation via VNC client Live operation via ToolScope Connector Live piece counter Machine utilisation statistics Tool utilisation statistics Piece counter, running time, reserve estimate Piece counter, running time, reserve estimate Operating time, standstill, active programmes, use of monitoring, rework, calibration, etc. Tool life quantity, tool life, changeover times, reasons for changes Technical data Real time Hard real time Soft real time Machine connections Profibus, Modbus, Profinet Network Network Cloud connection Network Network Network Response time Dependent on fieldbus, typically 20 ms 40 ms Dependent on network, CPU, typically 5 20 ms Processing frequency Typically 100 Hz, up to 5 khz in individual cases 100 Hz at 840D sl, 5 Hz at 840D pl Number of connected Unlimited Unlimited 1 16 machines per installation NC channels per machine 8 1 Unlimited Unlimited Autonomous data storage Data linking of machines connected around the world Data storage and provision in accordance with open standards Configuration of machine data into dashboards Visualisation of cloud data KOMET GROUP GmbH Zeppelinstraße Besigheim, Germany Tel. +49 (0) info@kometgroup.com T-08/17 Printed in Germany 2017 KOMET GROUP GmbH We reserve the right to make modifications.