Adaptive Machining, Real Time Vibration Monitoring

Omative Systems North America (Cincinnati, OH) debuted at IMTS 2014 with its proprietary, software-based systems for adaptive machining, real time vibration monitoring and shop floor production management.

ACM Adaptive Feed Rate Control reduces cycle time and protects the cutting process by monitoring the load and making real time adjustments to the programmed feed rate. ACM runs a test on the first work piece and “learns” the maximum spindle load for each operation. The user then sets an allowable override of the programmed feed rate, and from there ACM adjusts the feed rate for maximum efficiency based on the learned load value. When cutting conditions are lighter, feed rate is increased and cycle time reduced.

A brief demonstration of the Adaptive Control & Monitoring system optimizing machining feed rate to save cycle time and increase productivity.

Where the load becomes heavier due to unexpected workpiece hardness or thickness, the system reduces the feed, even to below the programmed rate, to protect the cutting tools and work piece. ACM automatically increases the feed rate to maximum during air cutting, then pauses and lowers the feed immediately prior to entering the material. In real world applications, ACM has reduced cycle times by 20 percent and more, depending on the application.

ACM can also prolong grinding wheel life by dynamically adjusting the feed rate to compensate for ongoing wear. The software can be installed on almost any CNC, including Siemens, Fanuc, Heidenhain and others, and receives all its inputs from the controller without the need for external sensors.

The VCM Vibration Monitor constantly compares machine and tool vibration against healthy baseline signatures, and issues alerts or shuts off the machine as instructed when values are exceeded. VCM reacts instantly to extreme events, such as collisions. After a collision, it can indicate whether there is internal damage. It also alerts the user to gradual changes in vibration that suggest maintenance is necessary. At the tool level, VCM can recognize broken tools, missing tools or improperly mounted tools, even changes as small as a broken insert on a face mill – critical for companies considering “lights out.”

PRO Shop Floor Management software is an ideal tool for optimizing processes and OEE by reporting machine performance data to remote computers from any CNC running ACM. It provides real-time, graphical information on machine availability, cycle times, cutting tool performance, alarms, cycle-time saving from ACM, parts production and other data. The software works seamlessly with any CNC where ACM is installed.

Proven effective and in use worldwide by top customers and OEMs, these software products are now available to North American shops and machine tool builders with direct sales and support by the new U.S. company based in Cincinnati.

Omative Systems North America, 9435 Waterstone Boulevard, Suite 140, Cincinnati, OH 45249, 513-444-2156, Fax: 513-444-2099, www.omative.com.