Application Report EMCO VERTICAL TURN 250. Data transmission: Digital CNC control: Siemens 828Dsl Cutting material: Steel

Transcription

1 Application Report for a Vertical Turning Center by EMCO VERTICAL TURN 250 with the monitoring system Toolinspect Data transmission: Digital CNC control: Siemens 828Dsl Cutting material: Steel This document is provided for information purposes only and is subject to technical modifications.

2 The tool and process monitoring system TOOLINSPECT provides the following advantages for series production of parts: Only minimal modifications in the NC program are necessary. A brief instruction for the machine operator is sufficient. Can be operated using 3 function keys. Can be used on analog and digital control systems of Siemens 840D / 840Dsl /828Dsl, Bosch, BoschRexroth, Heidenhain, FANUC and Indramat. A self-optimizing monitoring algorithm helps to reduce set-up and positioning times considerably, and adapts the monitoring parameters automatically to the different states of the operation (temperature, tool wear etc.). TOOLINSPECT boxes are available with Profibus-DP1 and Profinet-PN. Machining with very short process times <0.2s can be monitored. Cutting processes can be optionally upgraded to adaptive control. The resources of the CNC control panel computer are taken up minimally. An upgrade for the provision of MDA data from the PLC is possible. Monitoring system: TOOLINSPECT is a device used for monitoring tools on cutting machines. The data necessary for this task is preferably transferred from a CNC control system to the device via a Profinet PN / Profibus-DP port. The integrated software selects the monitoring strategy on its own depending on the tool or the machining. The machine tool manufacturer determines and enters the necessary parameters for a machine type one time. After that, no modifications or adjustments in the NC program, or via the visualization interface are needed. Fig. Siemens 828Dsl Integration Visualization on the control panel (starting Win98) is connected with the hardware via a TCP/IP or RS232 port. Alternatively, visualization can be achieved using an additional control panel. page: 1

3 The EMCO Group The success story of the company founded in Austria in 1947 began with the manufacturing of conventional lathes. Since then, the EMCO Group has evolved into one of the leading machine tool manufacturers in Europe, with manufacturing bases in Austria, Italy and Germany. The group is made up of an association of top-level European suppliers (EMCO, FAMUP, MECOF and MAGDEBURG) from the machine-tool sector, which together create intelligent production and training solutions for the machining industry in line with the principles of "Made in the Heart of Europe" and "Design to Cost". A comprehensive range of products, and the outstanding manufacturing quality and functional design of these products have made the EMCO Group the unrivaled expert partner for lathes and milling machines. The EMCO VERTICAL TURN - VT250 Designed for heavy-duty machining, the VT 250 is equipped with an integrated self-loading system, and needs little floor space. High productivity, highly accurate repeatability and enhanced operability are among convincing features of this product. page: 2

4 Test result and operation: After the installation, the machine was driven with a steel workpiece. The Toolinspect system was able to reliably monitor, with default setting, millings and drill machinings starting 3.5mm and thread machinings starting M6 via the driven tool of the turret. As the system has been designed to operate using 3 function keys, the operating staff did not need more than a brief instruction. The operator does not have to adjust any parameters or threshold values. The system makes these optimizations after the teach-in automatically during the production of the first workpiece. User interface for the operation of TOOLINSPECT The user interface is integrated in the AUTO operating mode under 'Machine Automatic': page: 3

5 General conditions: In machinings there are always different process data with dissimilar torque values and process variations. EMCO Vertical Turn - VT250 turning centers have 2 Toolinspect monitoring channels independent of one another. (channel1= spindle and the corresponding data to channel2 = turret) Monitoring reliably depends mainly on the ability to have machining signals reproduced consistently. Figure 1 (facing) shows the spindle and the axes drive torques. They show the machining with a lathe tool. We can achieve full, one-hundred percent monitoring with these measured variables. Fig.1 Signal display with machining and double-machining (no chip removal) Figure 2 (longitudinal turning) shows the spindle and the axes drive torques. They show the machining with a lathe tool. We can achieve full, one-hundred percent monitoring with these measured variables. Fig.2 Signal display with machining and double-machining (no chip removal) page: 4

6 Figure 3 (centrical drilling) shows the spindle and the axes drive torques. They show the machining with a drill. We can achieve full, one-hundred percent monitoring with these measured variables. Fig.3 Signal display with machining and double-machining (no chip removal) Figure 4 (drilling using a driven tool) shows the spindle and the axes drive torques. They show the machining with a twist drill. We can achieve full, one-hundred percent monitoring with these measured variables. Fig.4 Signal display with machining and double-machining (no chip removal) page: 5

7 Summary: Operating the device is very straightforward, and the CNC program needs minimal adjustments. When there is a change in type or technology, or in case of reprogramming, the operator does not have to make any readjustments. The system adapts automatically to different operating conditions (tool wear, variation in temperature etc.). The installation is comparatively simple. The adaptation in the PLC program, the integration in the control system, and the data link via Profibus-DP / Profinet-PN or TCP/IP port is structured very clearly and flexibly. Alternatively, TOOLINSPECT can be connected to the operating computer via a serial port. MCU GmbH & Co. KG: For more information regarding sales, distribution and projects, please contact our sales office - MCU GmbH & Co. KG in Winnenden. Address: MCU GmbH & Co. KG Sales Office Max Eyth Str. 51 D Winnenden Phone +49 (0) Fax +49 (0) sales@mcu-gmbh.de Internet: EMCO MAIER Limited Liability Company For more information regarding sales, distribution and projects, please contact EMCO MAIER Ges.m.b.H in Hallein-Taxach. Address: EMCO MAIER Ges.m.b.H. Salzburger Str. 80 A-5400 Hallein-Taxach Phone +43 (6245) Fax info@emco.at Internet: page: 6

8 Information on the product data sheet Pictures of the control systems and drive modules have been made available by the corresponding control unit manufacturers, and are protected by copyright. The data has been provided as non-binding general information. They are subject to change without prior notice! MCU GmbH & Co. KG, Maierhöfen page: 7