Requirements of modern manufacturing

In view of the world market situation, companies today have to pursue a strategy in their production that ideally combines productivity, quality and flexibility and offers the prerequisites for continuous improvement. Montronix solutions play a central role in defining and executing a successful manufacturing strategy.

Montronix Solutions

Montronix solutions are a must for all machine tools, but also for many other production plants and parts of plants. They enable continuous process monitoring and real-time detection of machine and tool collisions, tool breakage, idle cuts, overloading, excessive tool wear, unusually strong vibrations of the spindle and machine structure, and many other deviations from normal process behavior. These damage the manufacturing system and drive up costs. Thanks to Montronix, you can safely run your machines with a higher throughput and often even need fewer staff.

Productivity

In global competition, manufacturers can no longer avoid "lean production" - i.e. increasing productivity while reducing the resources used. Faster machines, a higher degree of automation and shorter downtimes are the basis for more productivity. Montronix solutions can help:

• They allow machining with fewer personnel at higher cutting speeds.
• They reduce machine downtimes by detecting impermissible processes such as collisions and tool breakage, but also machine wear.
• You prevent costly damage to machines and components.
  
  

Quality

Companies around the world are increasingly recognizing that a high standard of quality can ultimately be more cost-effective than a low standard. Montronix solutions enable cost reduction with increased product quality:

• Scrap and rework are reduced.
• The immediate detection of tool and process problems is important for ensuring part quality.
• The effort for manual tests (visual inspection / with a feeler gauge) is reduced, the space requirement is significantly lower.
  
  

Flexibility

In order to be able to react quickly to market changes, your production must be flexible. Smaller batch sizes, reduced inventory and shorter lead times are essential for bringing new products to market in the short term. Montronix offers tool monitoring systems to help you analyze the flexibility of your manufacturing:

• Self-learning routines ensure that the monitoring function is set up quickly for new work steps.
• The storage of component-specific system parameters saves time during conversion.
• The powerful, adaptable software enables the effective monitoring of a wide variety of manufacturing processes.
  
  

Continuous improvement

Fewer bottlenecks, higher throughput, less variability and better quality - all these goals require the collection, storage and analysis of plant data.

These are provided by Montronix:

• Selected process events are stored in system memory as soon as they occur. They are provided with a date/time stamp and are displayed graphically.
• With the help of the data provided, machine availability time, cycle time and tool use can be evaluated and complications can be specifically investigated.
• The visualization and storage of production data on a PC plays an important role in the analysis and continuous improvement of processes.
  
  

One or more station process monitoring for all machines

SPECTRA™ is an excellent solution for tool and process monitoring on all types of machine tools, in up to 4 machining stations (4 NC channels) with various tools and component programs. SPECTRA™ reliably detects collisions, idle cuts and excessive tool wear or damage and, thanks to its user-friendly visualization software SPECTRA™ hmi, enables process diagnosis and process optimization. SPECTRA™ is a microprocessor-based, multi-station, multi-sensor monitoring platform. SPECTRA™ can be programmed for up to three limit values ​​per sensor and up to three sensors per tool. With a library of user-selectable software algorithms, SPECTRA™ covers a multitude of different applications. Thanks to these proven, intelligent algorithms, the user can implement an application-related monitoring strategy and thus monitor the process precisely and reliably for scatter and errors. SPECTRA™ uses the graphical display of the machine HMI or an additional touch panel with the SPECTRA™ hmi software from Montronix as the human-machine interface. Both options offer an intuitive user interface that supports the user in visualizing and evaluating the current process status, makes it easier to identify and rectify faults, and enables parameter programming and adjustment. SPECTRA™ offers maximum flexibility in terms of application and connection options. Interfaces to controllers with conventional or open architecture are available. The modular design supports all Montronix sensors as well as those from other manufacturers, including digital drive data monitoring via Profinet or Profibus. SPECTRA™ can be networked via a local fieldbus and production networks. The possibility of remote access via the Internet or intranet creates the conditions for remote diagnosis and teleservice.

A sensorless option for process monitoring

Digital drive data DDD are the standard or an excellent extension of the Montronix SPECTRA™ process monitoring. A corresponding monitoring can be based exclusively on DDD data, but can also be implemented in connection with external sensors. With the help of the Digital drive data can be monitored for up to 16 drives or axes. In addition to DDD, conventional sensors can also be used. This enables very extensive and precise recording of process differences. All machine types can be monitored via the DDD drive data. The prerequisite, however, is an "open" CNC control from Siemens, Fanuc or Indramat. The DDD bus data is read in either via Profinet or Profibus. The SPECTRA™ SL and GL systems are to be used as an external solution (in the control cabinet). . This allows the machine manufacturer to integrate the systems quickly and individually. Retrofitting by the end customer is also possible without any problems. The adaptation of the DDD bus data is based on the same principle as with all other sensors. The procedure for setting the parameters can thus be retained. The operator decides which of the measured drives provides the most meaningful signal. The monitoring parameters are then set automatically. The advantages of the Montronix DDD bus data are:

• Easy integration with “Open CNC”
• Monitors bus data from up to 16 drives or axes
• Additionally monitors up to 8 external sensors.
• Due to the bus interface for data acquisition, no external sensors are required.
• Monitors tool breakage and wear.
• Serves for preventive maintenance.
• Monitors "Machine Overload"
• Monitors machine collisions. A suitable physical sensor (force or vibration sensor) must also be used here.
  
  
  

Montronix sensors - everything you need for your monitoring!

A sensor for every application

Description:

By integrating sensors in machine tools, important process data can be recorded in real time and conclusions can be drawn about the process. These can be machine, tool, workpiece and machining problems. Montronix has a variety of sensor types and the corresponding sensor technologies. This achieves a decisive competitive advantage in tool and process monitoring. The Montronix tool monitoring analyzes the individual sensor signals in order to detect tool errors and process problems. A mature signal processing technology enables the detection of events such as:

Collisions, missing tools, missing parts, tool breakage, tool wear, and overload and material cutting problems.

The prerequisite for the detection of abnormal process states is a conscientious sensor selection and the appropriate sensor placement.

Different Montronix sensor options:

Various research studies and extensive practical experience have shown that different monitoring tasks require different sensor technologies. Each sensor type has certain advantages and disadvantages.

In order to cover a wide range of applications, it can make sense to combine the different technologies. The various sensor types that help solve your individual process problems are described below.

Effective power sensor

The PS200-NG active power sensor records the active power consumption of spindle and feed drives via current and voltage. In this way, a statement can be made about tool wear, tool breakage and missing tools in the case of rotating tools. This sensor is usually installed in the control cabinet and can monitor AC and DC. It is easy to install and is ideal for new installations and retrofits. In addition, the DGM (Digital Gain Module) with the microprocessor unit offers further options for processing the measured values ​​of the PS200-NG. The measured values ​​are amplified, filtered and the idle portion is subtracted. Due to these properties, the sensor can be used for tools with very high and very low power consumption. Extremely small power changes (<0.002%) can be detected, allowing drills with a diameter < 1 mm can be monitored on large spindle drives.

AccuTorque™ torque and feed sensor

The AccuTorque™ Sensor AT100 allows direct measurement of torque and feed force of cutting tools. There are basically three versions available for application on spindles or tool holders. The rotor/stator unit can then transmit the measured signals wirelessly through an air gap of up to 5 mm. Torque measurement is useful for rotating tools where no meaningful power measurement is possible. AccuTorque™ is particularly suitable for thread cutting processes and multi-spindle applications and is used, among other things, to check the thread depth. The direct detection of the feed force enables a reliable "missing" detection. Another component of the AccuTorque™ sensors is an amplifier for signal conditioning. Its housing corresponds to protection class IP67 and can be installed in the wet area of ​​the machine. The amplifier is connected to the sensor stator via a 5 m long cable.

RetroBolt™ Force Sensor

The Montronix RetroBolt-Mxx-ICA DF (Mxx stands for a screw size M10/M12/M16/M20) is a 1-axis piezoelectric force transducer that emits signals through compression and tensile forces. The sensor ring corresponds to a "thick" washer and is used for screw assembly. The RetroBolt™ is installed in connection with stable washers as a package under screws and measures their elongation. This stretching is caused by the cutting forces during a machining process. The RetroBolt™ provides true force monitoring without having to modify the machine. As a "retrofit sensor" it can be installed quickly and easily on machines with screwed-on turrets and tool blocks. A classic example for a lathe is the cutting force monitoring of turning tools. Then the RetroBolt™ DF is installed with a turret mounting screw. RB force sensors are used to detect overload, collisions, missing tools and major tool breakages. A RetroBolt™ force sensor also includes a TSFA2-DGM amplifier for signal conditioning. In addition to the static force signal, the amplifier also offers an output for the dynamic component of the sensor signal. Its housing corresponds to protection class IP67 and can be installed in the wet area of ​​the machine. The amplifier is connected to the RB force sensor with a 5 m cable.

One-axis force sensors for milled pockets

The Montronix FS11CXK-ICA is a 1-axis piezoelectric force transducer that is installed directly in the force flow. The integration of the charge amplifier makes this sensor ideal for industrial applications. This results in high sensitivity, low drift behavior and a low-impedance signal output. It is installed in milled pockets or in force measurement plates, which are located directly in the machine structure. This sensor technology is ideal for lathes, presses and broaching machines. 1-axis force sensors are used to detect collisions, missing tools, tool breakage. Can also be used for tool wear in certain applications. A 1-axis force sensor also includes a TSFA1-ICA amplifier for signal conditioning. Its housing corresponds to protection class IP67 and can be installed in the wet area of ​​the machine. In addition to the static force signal, the amplifier also offers an output for the dynamic component of the sensor signal. The amplifier is connected to the ICA force sensor with a 5 m long cable.

Broadband vibration sensor BV100

The BV100 broadband vibration sensor measures mechanical vibrations (up to 10 kHz) in the machine structure, which are caused by the cutting process. It is used to detect collisions, missing tools, tool breakage and other process errors. The BV100 also measures the high-frequency AE structure-borne noise signals (50 kHz - 400 kHz). These also result from the machining process and are ideal for monitoring very small drills and taps. The structure-borne noise sensor is suitable for almost all machine tools, is very easy to install and can also be used as a retrofit. A BV100 vibration sensor also includes a TSVA2-DGM amplifier for signal conditioning. Its housing corresponds to protection class IP67 and can be installed in the wet area of ​​the machine. The amplifier is connected to the BV100 with a 5 m cable.

The length of the connection cable from all signal amplifiers to the SPECTRA™ electronics unit is 15 or 30 meters.