Optimizing Process and Tools for Grinding. Modular Process Monitor System PROMOS. operator-supporting uncomplicated retrofittable simply good

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1 Modular Process Monitor System PROMOS ð Visualized sensor or process signals (process analysis) to optimize your operation ð Shorter piece times, less scrap, better quality ð Operation and Visualization can be integrated in open NC Optimizing Process and Tools for Grinding ð GAP control ð CRASH control ð DRESS control ð TOUCH dressing ð SIZE touching ð ADAPTIVE control ð ROUND OUT control ð CHATTER control compatible with automated balancing equipment from MPM Sensors for grinding machines, Operating and visualization example operator-supporting uncomplicated retrofittable simply good PDA GB

2 PROMOS - the key to unlock your rationalization potential In automated production, interest is increasingly focused on process reliability. Low-cost, competitive production is possible only with controlled and optimized machining processes. In the grinding machining field, this results in a demand for effective on-line monitoring of tools and processes, together with a process analysis system which can be adapted to a wide range of machine tools and grinding processes tasks - like PROMETEC s Modular Process Monitor System: PROMOS. Despite its great flexibility and wide range of options for all modules - sensors, machine interfaces, monitor units and control modules - PROMOS is uncomplicated, simple to install and user-friendly. PROMOS always gives you the optimum low-cost solution - from simple spark-in detection (GAP control) to an all-round system which visualizes your grinding operation for process analysis and optimization and gives you 100 % process control. Reliability is the crucial factor! That s why all PROMETEC monitoring units for grinding operations - including PROMOS - come complete with CRASH control. Optimizing Process and Tools for Grinding - PROMOS will meet your demands Whether you make use of the full range of modular options for monitoring, control, visualization, machine interface or sensors, or use only selected elements, the systematic modular concept embodied in PROMOS opens the way to monitoring applications which we can optimize to fit your particular operation. You get maximum functionality at low cost with no complications. System architecture Sensor signals are analyzed by monitor modules. Different models with different options in terms of the range of monitoring functions and the number of monitored cycles (operation steps) are available. You can also choose modules in singlechannel or two-channel versions. For example: a two-channel monitor module is the lowest-cost solution for a grinding machine with two grinding spindles, where a single-channel monitor module would be the standard choice for a grinding machine with only one spindle. With PROMOS you Co-ordinate grinding machine application can operate up to 15 monitor modules from the same operator panel module. Sensor-specific sensor modules or sensor terminals are available to feed sensor signals to the monitor module. Cylindrical surface grinding machine application The monitor module transfers alarms (breakage, wear etc.) to the machine SPC via a machine interface module. The interface module is supplied in a number of variants, including the BAPSI standard or the MINI version, respectivlely, which is sufficient for grinding machines most of the time. PROMOS Modules Operator Panel Modules You have the choice: The Modular Process Monitor System can be operated either from a PROMETEC operator panel module, from a PC or laptop or directly from an open NC control system, using appropriate PROMETEC software. With the operating software for the PROMOS modular Process Monitor System you have your process under control the software comes complete with the OPM 20 operator panel module or as a special package for open NC controls and PC s. PROMOS system architecture (example)

3 Apart from controlling monitoring operations, the OPM 20 or the standardised software provides extensive options for visualising the signal and hence for diagnosing and optimizing machining operations. The very low-cost OPM 12 control module can also be used to set up the monitoring system without difficulty, even for complex machining tasks. A bar display shows the limits and the signal. The user-friendly menu structure is identical with the OPM 20 software. Both control modules are fitted with a serial interface (RS 232) for the transfer of monitoring data between NC, PC, NCfeeder, cell computer etc. and the monitor modules. This means that the monitoring system can be re-set automatically after a tool change. Given a laptop, a modem and a telephone (cellular phone) you can use the RS 232 interface for remote diagnostics and remote servicing of the Modular Process Monitor System by the machine manufacturer or PROMETEC. With a laptop and the RS 232 interface, you can also use the OPM 12 operator panel module to visualize the sensor signal and carry out user-friendly commissioning and servicing functions. Operator panel modules are fitted in the front panels of control stations etc. Alternatively, the OPM 12 operator panel module and the plug-in module can be supplied for 19 rack fitting with 3 HE. There is also the option of fitting both operator panel module types in a protective enclosure for wall and freestanding fitting. In this case, the on-board RS 232 and printer interface have standard external connections. Monitor module type Channels Cycles per channel Limits MSL of 6 MSL of 6 MSL of 6 MSL of 6 MSL of 6 MSL of 8 MSL of 8 MSL of 8 MSL of 8 MSL of 8 Monitor Modules The monitor modules in the MSL 3000/5000 series use fixed limits. So that optimum prices and functions can be offered for specific machining tasks, the modules are designed for between 2 and 250 monitorable cycles and 2 to 6 different static limits. The static limits are used for monitoring; appropriate limits for each monitoring cycle are chosen from a group of 6 to 8 thresholds. They are related to the sensor signal for normal undisturbed machining. The various monitor modules perform their monitoring tasks separately, optimized for each work station. The sensor signal for each cycle is calibrated automatically in a teach-in (or manual) phase during machining of the first workpiece and the limit positions are specified. Monitor modules in the MSL 5000 series have extended monitoring functions like storage of monitoring data under the appropriate program number. Standard assembly of the monitor and sensor modules is in an EMV-proof protective enclosure supplied with the package and designed for fitting in a switch cabinet. Limit type Overload Underload Contact Missing (switches at end of cycle) Rising through Falling through (MSL50xx only) Work over Work under (switches at end of cycle) Example Type OPM 12 OPM 20 Display LCD 4 x 20 Charact. full-vga color or monochrome l RS 232 for PC, l modem etc. Printer interface LPT m l Plug-in module for optional optional ext. connector RS232 or printer interface Protective enclosure optional optional Machine Interface Modules All machine interface modules are supplied in appropriate EMV-proof protective enclosure for fitting in a switch cabinet. The main functions of the 3 interfaces are shown in the accompanying table. Please refer to the interface plans or descriptions for further details. All signal inputs and outputs on the MIDI and MINI machine interface modules comply with the BAPSI standard. Machine interface module Type 1-channel Cycles Alarm outputs 2-channel Cycles Alarm outputs MINI MIDI BAPSI one additional common output for both monitoring channels For 2-channel operation and two BAPSI interface modules

4 Sensors PROMETEC offers a comprehensive range of effective, reliable sensors, proven in thousands of industrial applications. Grinding operations are monitored by standard acoustic emission sensors fitted on the headstock or dresser unit. The AEL 200 structure-borne sound sensor can also be mounted directly on the end of the spindle, with wireless signal transmission. This technique offers particularly high resolution, with an excellent signal-to-noise ratio. Other PROMETEC sensors may be used for special applications. Fluid sound sensor for structure borne sound and accoustic emission via coolant flow from workpiece Wide band sensor for structure borne sound and accoustic emission Inductive displacement sensor for force and elongation Wireless sensor for structure borne sound and accoustic emission Hall current sensor for effective power Fitting of wireless sensor at the end of spindle Sensor and transmitter Receiver Accoustic emission and vibration sensor PROMOS combined with MPM balancing units Complete sytems from a single supplier MICRO PRÄZISION MARX GmbH in Erlangen and PROMETEC GmbH, Aachen joined forces in June 1996 to develop and market ancillary systems for grinding machines. MPM makes manual, semi-automated and fully-automated balancing units for grinding wheels. The low-priced high-precision units use a wireless remote control for the balancing motors the CONLESS system. MPM and PROMETEC have made their systems compatible. PROMOS system components are also easy to combine with MPM automatic balancing equipment. If you prefer, you can order the complete package from a single supplier PROMETEC or MPM. Change of balancing mass value and position Automatic balancing unit from MPM combined with PROMETEC grinding and dressing monitoring

5 Dimensions and connection data Operator panel module OPM 12 Operator panel module OPM 20 Views (not to scale) Dimensions for front mounting - in a 19" system - with protective rails Mounting cut-out for front mounting Drill holes for front mounting Dimensions of enclosure - without external securing latches - with external securing latches Drill holes for enclosure - without external securing latches - with external securing latches 106,5 x 128 x ,5 x 130 x x ,4 ± 0,1 x 122 ± 0,1 (4 x Ø3,3 or M3) 140 x 180 x x 200 x x x 192 / 271 x 172,5 x ± 0,3 x 156 ± 0,3 230 ± 0,1 x 163 ± 0,1 (6 x Ø4,3 or M4) 300 x 200 x 97 / 280 ± 0,1 x 180 ± 0,1 / Power supply 24 V DC ± 20%, 300 ma 24 V DC ± 20%, 850 ma Connection to monitor module 2 x 0,25 mm 2, twisted pair, screened, max. length 100 m, max. 50 m between 2 modules Monitor modules in compact protection box with space for 2 sensor modules Machine interface modules BAPSI or MIDI Machine interface module MINI Protection box Ÿ for panel mounting without top-hat rail holes for 2 x M4 screws 60 mm center-to-center Ÿ for top-hat rail fitting note 10.5 mm depth between monitor module and top-hat rail for snap-on elements! Dimensions without snap-on elements 67 x 106 x x 106 x x 106 x 89 Power supply 24 V DC ± 20%, 600 ma 24 V DC ± 20%, 600 ma Power supply from monitor module Connection monitor/ interface modules 2 x 0,25 mm 2, twisted pair, screened, max. 50 m length Short ribbon cable

6 Examples how to optimize your grinding process with PROMOS: GAP control TOUCH dressing & SIZE touching ADAPTIVE control: Reduced air grinding time via GAP control (contact detection) Reduced piece times Reduced costs Enhanced process reliability due to integrated CRASH control function Automatic introduction of the grinding wheel for tooth flank and thread grinding etc. Visual monitoring of the dressing operation Low infeed with TOUCH dressing Determining exact grinding wheel radius via machine control by means of highprecision contact detection - SIZE touching Low-infeed dressing confined to projecting grits - TOUCH dressing No surface sharpening needed, since grinding capacity of the wheel is unaffected Adaptive control for grinding large eccentrical or noncircular parts Fast detection of maximum workpiece diameter related to workpiece fixture via contact detection Time saving via circumferential speed control referred to grinding / air cut via variation of workpiece speed Minimized consumption of abrasive through sensor-assisted dressing infeed Long grinding wheel life ADAPTIVE control: DRESS control: Reduced dressing strokes Minimized grinding wheel costs Improved quality due to monitoring of dressing results Visual Control of dressing process Post-process workpiece fault detection during dressing (see figure): Grooves in grinding wheel ð welts on the parts ð check parts up to last dressing operation ROUND OUT control with grinding and dressing Removal of concentricity mistakes Monitoring the required concentricity in grinding and dressing operations No unnecessary stock removal in cylindrical grinding. The process can be interrupted as soon as the required part concentricity is attained. Monitoring the workpiece for waviness Achieving high concentricity in dressing operations, with special attention to dynamic signal components in the monitor Improved part quality with concentric grinding wheels CHATTER control Enhanced quality through detection of chatter phenomena from the signal dynamics Adaptive control for co-ordinate grinding Time saving through controlled feed movement Improved quality through determination of effective grinding wheel diameter, SIZE touching Sensor-controlled deburring Grinding wheel contour tracing Exact workpiece position determination Shorter air machining times Grinding wheel diameter compensation Reliable contour tracing PROMETEC GmbH Jülicher Str. 338 D Aachen Tel.: 0241/ Fax.: 0241/ Quality assurance systems, sensors, monitoring systems for machines, processes and tools Daugther companies and representatives in Europe, America und Asia Your representative: