GIORNATA DI STUDIO SU UTILIZZO DI SENSORI PER IL MONITORAGGIO DI MANDRINI PER FRESATURA E RETTIFICA

Transcription

1 GIORNATA DI STUDIO SU UTILIZZO DI SENSORI PER IL MONITORAGGIO DI MANDRINI PER FRESATURA E RETTIFICA Usage of sensors in the spindles for high performance cutting and precision machining State of art and new technology Contents 1. Introduction 2. Spindle integrated sensor 3. Case study of high performance cutting a. SmartVision b. SmartDrive 4. Case study of precision machining a. DMD b. Shaft cooling

2 Fischer AG Precison Spindles - Founded In the second generation of family ownership - Location Herzogenbuchsee Employees Fischer Precise Group: 3 Brands 7 Locations Rotation ~ BC. The name stands for PRECISE, FAST and POWERFUL rotation

3 Quo vadis? Precision Speed Power / Torque Precision parts Grinding High Power Surfaces Small tools High Torque Bearing Ball bearing Air bearing Hydrostatic Magnet Angular contact ball bearings Cylinder roller bearings and others Static Compressed air is introduced Dynamic Air cushion is built up by the movement itself Static Liquid is introduced under pressure Dynamic Pressure in the fluid builds up by the pumping action of the two part surface Contact free Bearing forces is generated by controlled electromagnets

4 Contents 1. Introduction 2. Spindle integrated sensors 3. Case study of high performance cutting a. SmartVision b. SmartDrive 4. Case study of precision machining a. DMD b. Shaft cooling Sensors Bearing temperature Force flow of bearings Motor temperature Shaft angle position Axial position of interface Flow rate Structure acoustic noise Leckage Number of tool changes Vibration level Current Voltage Speed

5 Sensors Visualize the condition of the spindle Records the measured datas Analysis exceeded warning levels Registered alarms Allows to create reports Smart Vision Safe operation of spindle Optimization of the machining process Sensors Schnitttiefe a p [mm] F rä se r , D stabiler Schnitt l ge s = m m, l a = 4 8 m m R a tte rn 2 Schneiden, Vollhartmetall Experimentelle Stabilitätskarte Vollnut, fz = 0,18 mm Drehzahl [1 /m in ] I total = 139 mm I a = 48 mm stabiler Schnitt R a tte rn Experimentelle Stabilitätskarte F rä s e r N r , D 1 6 l g e s = 1 6 6,5 m m, l a = 7 5,5 m m 2 Schneiden, Vollhartmetall V o lln u t, f z = 0,1 8 m m Schnitttiefe, a p [mm] Drehzahl [1 /m in ] I total = mm I a = 75.5 mm

6 Sensors Machining forces 5 revolutions Force [a.u.] Time [a.u.] SmartVision Report Customer send his recorded SmartVision Data back for analysis by Fischer Engineers. You will get back an analysis of: Productivity of the machine Spindle power and torque utilization Spindle speed utilization Observations by experienced spindle experts Recommendations for improving spindle reliability

7 Contents 1. Introduction 2. Spindle integrated sensor 3. Case study of high performance cutting a. SmartVision b. SmartDrive 4. Case study of precision machining a. DMD b. Shaft cooling High Power Milling Example: Aeronautical structure parts With spindle power of over 150 kw material removal rate of > 15 l/min are achievable. Fischer converter for high power MFW-2715/ kw, 96 Nm S1 MFW-2320/ kw, 48 Nm S1

8 High Torque Milling Example: Structure parts for energy generation High torque for roughing and high speed for finishing are necessary to mill difficult machinable materials with long tools MFW-2801/ Nm, 28 kw S1 MFW-2702/ Nm, 93 kw S1 SmartDrive Strong Current up to 300 A eff, sufficient for spindle power of 200 kw Fast Special modulation method up to 20 khz: high torque and high speed in combination Current control loop cycle time 2 µs Sensor Signal processing, including recording in 0.2 ms cycle time [PLC Function] Intelligent Design One connection for all Spindle Sensors Spindle Electronic on Board PC integrated for monitoring of spindle sensors

9 SmartDrive Process Analysis View through the Spindle Process Analysis of Speed Torque Power Vibration at the Cutting Edge Integrated Oscilloscope Highest Resolution Detailed Information Communication to CNC Control Exceeding of limit values Quick Signal variation during processing Envelope monitoring or Teach-in Cycle to optimise the Cutting Process Contents 1. Introduction 2. Spindle integrated sensors 3. Case study of high performance cutting a. SmartVision b. SmartDrive 4. Case study of precison milling a. DMD b. Shaft cooling nano

10 Thermal constant process condition Benefits 1. Shortening the time until saturation of temperature Shaft cooling Time reduction -80% Spindle temperature Without shaft cooling Shaft cooling Time Thermal constant process condition Benefits 2. Reduction of shaft elongation Shaft cooling Dilatation -70% Without shaft cooling Shaft cooling Zeit

11 Displacement Measuring Device Compensation of thermal and mechanical spindle growth Thank you for your attention Senior Engineer Fischer AG Präzisionsspindeln 3360 Herzogenbuchsee