Application report matec-30 S / SD milling machine of the monitoring system Toolinspect Data communication : Digital CNC-control : Heidenhain itnc530 Removed material : ceramic glass This document is for information purposes only. Technical modifications reserved.
The company in Köngen matec Maschinenbau GmbH is situated in the swabian Köngen and at present employs over 150 people. Since 1992 the company has been producing CNC machining centers with travelling column as well as gantry machines (turning option is available on request). The production plant where the company moved into in 2001 combines administration and production facilities on 3000 square meters of floor space. Böhm Fertigungstechnik Suhl GmbH, a competent supplier in the machining industry is a copartner of matec Maschinenbau GmbH. Both companies belong to Böhm AG. Matec machine tool conception is based on standard machines as well as custom-made machines. Planning is always based on our customer s specific machining tasks. Choosing a basic machine from our programme marks the beginning of each planning. A great variety of options, e.g. CNC round and tilting tables, 5-axes milling heads, infinitely variable NC heads, linear drives, handling systems, tools, and devices turn basic machines into complete solutions. The clever-engineered matec modular component system allows to cover nearly all customer requests in metal cutting. Maschine: matec-30 S The swivel table machine from matec was developed for the series is entitled to the high level of cutting. Stability, precision and speed characterize these machines. A 180 swivel table belongs to all machines in this series as standard. It allows a quick part exchange and thereby brings high productivity. The matec system design with its extensive service packages enables a variety of machine concepts to bring to every user the optimal manufacturing solution, and thus secure for him a clear competitive advantage. The basic machine matec-30 S is available in two sizes, covering almost all common workpiece dimensions of mass production. The SH version is a particularly compact and flexible machine with small footprint, the SD is designed for twin-spindle machining of large workpieces and demanding appropriate and the SHV with angled head for the horizontal and Vertikalbearbeitung of 5 pages and the 3D processing in the volume. Handling systems, equipment and automation solutions to make the swivel table machine flexibility for every application. Seite: 1
Advantages in connection with the tool- and process monitoring system series production., in at the development the simple operation and minimal imbeddings were in the centre in the NC programme. a small instruction of the using staff is sufficient for Toolinspect Simple operation via 3 functionkeys. Choose between 19 languages. the system becomes (shift, milling, drill, graters, threads etc., at different CNC engines with different process.) Toolinspect can be operated with the common CNC controls. (Siemens, Bosch Rexroth, Fanuc, Indramat, Bosch, Heidenhain) process fluctuations are recognized automatically and the supervision limits adapt to the changes without intervention of the operator. automatic system and data saving on an external CF card. external module with mobile -- of one's own processor. Optional extension adaptive control of rough machining to reduce the processing time. automatic reconnaissance of tool change over tool magazine and therefore no operation necessary. torque and way information is selected from the CNC control. Higher processing speed can hereby be driven. a more exact supervision is guaranteed selection of processings in three single Sekmente by here: material touch (fluctuations) middle process (constant processing) finishing process (possible fluctuations) Further information: www.mcu-gmbh.de Monitoring straight after tool change. Process analysis with data interpretation for technologists and export function of the actual values and machine data to Excel. Robust flash memory Optional extension: storage of up to 250 different alarm messages for 96 hours. Seite: 2
Monitoring system: The device is used to monitor tools on metal-cutting machines. The data, necessary for this task are normally transmitted to the device by a CNC control via a Profibus-DP interface. The monitoring strategy is automatically selected by the integrated software, according to the tool or machining process. The necessary parameters are determined and entered individually for one machine type by the machine tool manufacturer. No changes or adjustments are then necessary in the NC program or via the visualization interface. Pic. 1 Rexroth Bosch Group MTX (visualization) Pic. 2 Siemens 840D (visualization) Pic. 3 Heidenhain itnc530 ( without visualization) Seite: 3
Process / Tools: It is machined glass plates with a matec 30-S engine in mass production. It is a component supplied from a special glass, and with different hollow bore from 10mm to 70mm with the 30 will be introduced matec-s machine. Visualization of the processes on the external PC: Processing without tool breakage: Evaluation on the external PC via Microsoft Office Seite: 4
Processing with tool breakage: Seite: 5
Operation Reset limits button This button resets the system for the active program (the program which is displayed in the interface under Prog. no.:) to the original values and relearn is carried out. Relearn button This button is used to carry out relearn. The program-specific data (increased limits) are not reset. The limits readjust to the actual values in the following machine cycles. Increase limits button If an incorrect message is generated by Toolinspect, the limit of the relevant fault message (switching threshold which generates a fault message) can be increased by pressing the F2 button. If this cut is reactivated in the next machine cycle, the increase of the limit is marked in yellow. ON / OFF button This button activates the tool monitoring and disabled. Seite: 6
Results: All tools are safely monitored, especially tools with low feed rate. Analysis of processing and optimization. Recognizing of missing coolant. Summary: The operation is imaginable simple and only a few modifications are required to the CNC program. The operator does not have to set any limits or parameters for monitoring. Not even at a change of the machined workpiece type or when new NC programs were written. The system adapts automatically to various operating states of the machine (wear, changes in temperature, etc) and selects the appropriate monitoring strategy automatically. The installation was proportional easy. The modifications in the PLC program, the integration of Toolinspect into the control and the data transfer via Profibus DP is extremely flexible and well structured. It s also possible to connect Windows computer. via TCP-IP or a serial interface with a Seite: 7
MCU GmbH & Co. KG: If you have any further questions concerning this application report, please contact the sales office of MCU GmbH & Co. KG in Winnenden. Address: MCU GmbH & Co. KG Vertriebsniederlassung Max Eyth Str.51 D-71364 Winnenden Telefon +49 (0) 7195-137538 Fax. +49 (0) 7195-137539 Mobiltelefon. 0172-7143327 Email : sales@mcu-gmbh.de Internet : www.mcu-gmbh.de matec Maschinenbau GmbH If you have any questions to the machine, please contact the company matec Maschinenbau GmbH in Köngen. Address: matec Maschinenbau GmbH Information on the data sheet Wilhelm Maier - Str. 3 D-73257 Köngen Tel. : +49(0)7024-98385-0 Fax : +49(0)7024-98385-30 Email: info@matec.de Internet: www.matec.de The images of the controls and drive modules provided are protected by copyright of the individual control manufacturers. All information provided is without guarantee of correctness. Subject to change! MCU GmbH & Co. KG, Maierhöfen / Germany Seite: 8