Protect your machine and tooling. Minimize damage resulting from collisions. Monitor and analyze your machine behavior

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1 Machine Tool protection and condition monitoring Protect your machine and tooling w w w. d i g i t a l w a y g r o u p. c o m Minimize damage resulting from collisions Monitor and analyze your machine behavior

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3 Machine Tool protection and condition monitoring w w w. d i g i t a l w a y g r o u p. c o m is a 3-axis accelerometer sensor and processor specially designed and built in Digital Way s lab to provide you with the most effective means for protecting your machines against damage resulting from a crash or a collision. Mounted on your machine s spindle, this powerful system also allows you to record vibration data associated with the conditions of machine use or with tooling quality. Why monitor vibrations? Vibration monitoring is a key strategy to ensure the quality of your production, to check your tooling, and your machine components. This is also the fastest way to detect a collision and stop your machine quickly enough to prevent damage and downtime. Consequences of a crash during a machining operation are generally catastrophic: - Broken Part or Tool-holder, - Damaged spindle, - Need to re-do all mechanical set-up, - Long downtime and production stoppages. system What for? To minimize consequences of a crash and to reduce the repair costs. Reduce cost How? Once installed on the machine, quickly detects a crash and immediately stops axis motion. On many applications Why? Small, easy to install and adjust, can protect machine tools, industrial robots, gantry systems, and industrial equipment. Machine Tool Velocity Minimizing crash damage The graph to the right shows the benefits of using the system when a crash occurs on a machine. When a machine stop is decided by an overcurrent alarm on an axis movement, it s often too late to avoid large damages to the spindle / tool / part fixture, leading to long downtimes and increasing your manufacturing costs. Of course, the will not prevent the crash, but its extremely fast reaction time will allow a much faster machine stop and thus a drastic reduction in the repair costs. Alarm Machine-Tool Axis Over-current Alarm Time to Machine Tool stop Money The Advantage Minimize crash damage by reacting fast to an impact and excessive vibration that involves spindles and/or part fixtures.

4 Machine Tool protection and condition monitoring w w w. d i g i t a l w a y g r o u p. c o m is available in several models, depending upon your needs and machine specifications. It can be used in «stand-alone» versions or as an addition to the Wattpilote to create the most complete monitoring solution for your machines and your tools. Most important: an industrial sensor Encapsulated in an M12 housing, the 3- axis acceleration sensor was designed to be a real industrial product. It is durable, compact, easy to install, and it has a quick-disconnect cable. In order not to be disturbed by the environment, the sensor output is digital: no need to take special precautions, the sensor cable can be mixed in the cable carrier system with the power supply cables for the spindle. For each type of machine, one solution The system may be used on any type of machine tool. It may also be used on many robotic applications (palletizer, drilling, deburring, or welding robots) and material handling machines such as gantries. Access Machine tool, Robot, Gantry Extand Transfer line, Robot Adaptable to all types of machining can be successfully applied on most kinds of machines: Machining centers, turning centers, grinding machines. It can be used only for machine protection, but it can also provide useful information about machine and tooling health. Premium Machining centers, turning centers, grinding machines Convenient installation in the electrical cabinet The signal processing box is mounted in the machine tool electrical cabinet. It connects to the PLC or machine control via a small number of discrete I/O. The 3-axis digital accelerometer is mounted on the spindle or part fixture. A quick-disconnect cable is between the processor and the accelerometer. MicroMon One touch set-up system The optional MicroMon graphical HMI display allows fast and easy process limit changes when production lot sizes are small: It's just necessary to activate one touch before the first part is machined and Micromon automatically analyzes vibration and adjusts parameters.

5 Successfully applied on most kinds of machines Easy to use No need to be a vibration expert to handle this system. Its simple interface has been specially developed to make it accessible to anybody, even without any knowledge about vibration sensing. Easy to install and set-up achieved with only a few clicks. Limit damage The vibrations in the X, Y, and Z directions and the RMS vibration are shown along the top of the screen. The Shock plot shows fastresponse impacts and the Vibration plot (actually RMS vibration) shows the time-averaged vibration level. With a reaction time of around 0.5 milliseconds, the will effectively reduce the damage resulting from unexpected events during your machining process. Ensure quality Excessive vibrations during machining are one of the main sources for degrading the quality of your production. This system will help you keep your machine working in good condition. Its very high sensitivity will also give you the ability to detect out-of-balance problems with your high speed tooling. Events record This system will act as a true black box that will allow you to track all unexpected events occurring during the use of the machine. Each alarm will be stored in the system s memory with the corresponding shock and vibration curve. Check Spindle health Keep an eye on the spindle condition by checking vibration levels in 3 different axes. Its very high sensitivity will also give you the ability to detect out-ofbalance problems with your high speed tooling.

6 Machine Tool protection and condition monitoring Machine control panel Electrical cabinet NC Interruption CNC 24V DC 3A PLC SW-A05 WE-M10 RJ-P01 WE-M10 WE-M01 SP-A0 Laptop PC SP-Visu-C Machine Tool CA-M15 Spindle WL-E05 AG-03M Single-spindle machine tool with numeric control Collision Excess Vibration Chatter Balance Machine analysis Spindle condition Technical characteristics Sensor Technology 3-axis digital accelerometer ± 16 g Sensitivity 4mg Maximum shock 10,000 g shock survival Sampling rate 3200 Hz Ambient temperature C Dimensions L 45 mm, Diam. M12 Protection rating IP 67 Weight 15 gram Technical characteristics Processor Access Extand Premium Power supply 24 VDC ± 10 %, 200 ma Number of different process Reaction speed 0.5 millisecond Collision control x x x Vibration control x x x Balancing control x x x Clamping control -- x x Saved events last Saved events curves last FFT analysis capabilities x x x Optional analog output available x PLC Interface 24 VDC 24 VDC Profibus Fast Inputs 24 VDC type II, 15 ma Fast Outputs Work contact static relay 24VDC Supervision Interface Ethernet - 10/100 Base Tx Communication protocol with sensor Numeric (CAN Network) Maximum length of sensor cable 80 meters reference Part Nr. Sensor Access Extand Premium AG-03M SP-A0 SP-E0 SP-PP

7 WattPilote & The best monitoring Machine control panel Electrical cabinet NC Interruption CNC 24V DC 3A PLC Frequency converter SW-A05 WE-M10 RJ-P01 WE-M10 WE-M01 WE-M01 WP-CN-S032+SP Laptop PC (Backup) WP-Visu-C Machine Tool CA-M15 Spindle WL-E05 AG-03M Single-spindle machine tool with numeric control WattPilote Tool Wear Tool breakage Insert breakage Missing tool Double machining Tool/Part contact Collision Excess Vibration Chatter Balance Machine analysis Spindle condition Technical characteristics Sensor Technology 3-axis digital accelerometer Measurement range ± 16 g Sensitivity 4mg Maximum shock 10,000 g shock survival Sampling rate 3200 Hz Ambient temperature C Dimensions L 45 mm, Diam. M12 Protection rating IP 67 Weight 15 gram Technical characteristics Processor Number of different process 120 (15 with WattPilote Transfer) Reaction speed 0.5 millisecond Saved events last Saved events curves last Fast Inputs 24 VDC type II, 15 ma Fast Outputs Work contact static relay 24VDC Communication protocol with sensor Numeric (CAN Network) Maximum length of sensor cable 80 meters WattPilote Evolution reference Part Nr. Single - Transfer - Contact - Turning Reference WattPilote + SP SP : Option Example WP-CN-S032+SP : WattPilote Single Evolution 32KW three phased spindle ProfiNet interface option WP-AN-S016+ SP : WattPilote Contact Evolution 32KW three phased spindle ProfiNet interface option WP-LN-S032/A008+SP : WattPilote Turning Evolution - 32 kw Main Spindle / 12 A axis ProfiNet interface Dual Triple - Quad Reference WattPilote + SP 0 0 : Number of channel SP : Option Example WP-DN-S032+SP2: WattPilote Dual Evolution 32KW three phased spindle ProfiNet interface 2 channels WP-QN-S016+SP1: WattPilote Quad Evolution 16KW three phased spindle ProfiNet interface - 1 channel

8 Machining / Applications Machines Access Extand Premium Embedded Machine Tool protection and condition monitoring w w w. d i g i t a l w a y g r o u p. c o m Selection guide Automatic boring machines with single tools Boring / deep hole drilling machines or multi-spindle machines Transfer machines and multi-station special machines Fully automatic milling machines Single-spindle machining centers and special machines Double-spindle machining centers and special machines Three-spindle machining centers and special machines Four-spindle machining centers and special machines Fully automatic turning machines and turning centers Special turning machines Surface, cylindrical, internal, and centerless grinding machines Industrial robots Machining robots Gantries Boring or deep hole drilling with single tools Boring, drilling or tapping using a multi-spindle head Drilling with a boring bar or a tool with multiple inserts Machining with complex cutting tools Boring with ¾ borer Rough machining, machining of raw parts Finishing milling Turning / rough milling, turning work on a rough part Finish turning work Beam drilling (cycle optimization) Crankshaft shaving Gear cutting Crash detection : Optimal performance : Works under certain circumstances : Not recommended

9 For each type of application, one solution Machining centers Gantries Swiss type machines Industrial robots Transfer lines Improve machine maintenance

10 mm Link 100M Digital Way Successfully applied on most kinds of machines Processor front view Link 100M Link 100M Digital Way Digital Way access extand premium RUN MON SLW ALR RUN MON SLW ALR DT1 DT2 2 DT3 DT4 RUN MON SLW ALR DIA ERR DT5 DT6 PWR GND Sensor PWR GND Sensor DT7 CPL DT1 DT2 PWR GND Sensor DT3 WFR WFR DT4 WFR BAL BAL DT5 BAL ACQ ACQ DT6 ACQ SLW SLW DT7 SLW ALR ALR CPL ALR COM COM GND COM Machine tool crash protection Machine tool crash protection and condition monitoring Machine tool crash protection and condition monitoring mm mm mm Processor left view Sensor mechanical dimensions Top view M12 x 1 Z Y X Left view mm mm M12 x mm mm Z Y X

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12 F R A N C E Digital Way SAS - Saint Etienne Tél.: +33 (0) contact@digitalwaygroup.com U N I T E D S T A T E S Digital Way Inc. Michigan Tel.: john.cosic@digitalwaygroup.com D E U T S C H L A N D Digital Way - Frankfurt / Main Tel.: joachim@digitalway.fr I T A L I A Angiolini Franco Milano Tel.: angiolini.f@gmail.com E S P A Ñ A Danffor Eibar Tel.: danffor@danffor.com Maquina Center Barcelona Tel.: sagullo@maqcenter.es