Real-Time Machine Shop Productivity

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Real-Time Machine Shop Productivity
Optimization Solutions
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Vibration Control Monitor (VCM)

• VCM continuously monitors machine tool vibrations
  during machining
• VCM analyzes the vibration data in real-time and
  issues warnings and/or stops the machine if
  unacceptable vibration conditions occur thereby
  preventing pending failures
• VCM provides information about potential failures
  and can call for preventive action based on the
  machines vibration signature analysis

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VCM Main Features

• Machine Vibration Signature Analysis
• Simultaneous Monitoring of up to 3 Machine
  Components
• Vibration Data Collection, Storage And
  Visualization
• Lifetime Utilization Histogram Representing
  Machine Condition History
• "Black Box" Post-Failure Vibration Analysis
• Tool-Specific Vibration Monitoring
• Tool Part Run Out Detection
• Fast Response Collision Detection

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VCM in Machine Environment
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VCM Configuration

• Accelerometer(s) installed on vibration-prone
  machine location(s)
• VCM Data Acquisition Hardware
• VCM HMI can be integrated into
• Stand-alone PC
• Siemens Sinumerik 840D
• OKUMA OSP-P200

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Overall Machine Vibration Monitoring

• VCM can continuously monitor the Overall
  machine, guarding against excessive vibrations in
  every machining operation in two ways
• Time-domain - VCM continuously measures a
  broadband of vibration acceleration, velocity,
  and displacement - according to the ISO 10816
  standard.
• Frequency-domain - VCM triggers alerts or alarms
  if the vibration exceeds its permissible band
  limits across the frequency spectrum

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Time-Domain Vibration Analysis

• VCM analyzes the vibrations in Time-domain in
  three configurable frequency ranges
• Low frequency band - with adjustable bandwidth,
  to determine the vibration displacement level
  (peak to peak) within this band.
• Medium frequency band - with adjustable
  bandwidth, to determine the vibration velocity
  level (RMS) within this band.

• High frequency band - with adjustable bandwidth
  to determine the vibration acceleration level
  (RMS) in this band.

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Frequency-Domain Vibration Analysis

• VCM uses Fast Fourier Transform (FFT) processing
  for
• Real-time frequency-domain analysis
• Vibration signature recording and analysis
• In real-time frequency-domain analysis, VCM can
  analyze up to 10 configurable narrow bands.

The bands may be selected based upon operating
conditions and expected fault vibration
characteristics.
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Tool-Specific Vibration Monitoring
By distinguishing between vibration behaviors of
various tools, VCM can automatically prevent
dangerous vibration conditions for each
tool. Tool-specific vibration monitoring is
carried out in both time and frequency domains.
Time-domain analysis determines the overall
vibration velocity level only within the medium
frequency band.
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Tool-Specific Vibration Monitoring Setup
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Vibration Signature Analysis
VCM enables preventive action to be taken based
on a comparison of

• Machines current vibration signature
• Machines reference vibration signature in
  healthy condition

The deviation is limited by an envelope around
machines reference signature.
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V-Signature Recording Storage
Direct NC program access to V-Signature recording
function. Start command initiates the recording
process. It is forced to stop either by achieving
required accuracy or by the Stop command. A
V-Signature file is generated and saved
automatically.
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VCMs Collision Detection

• VCM interprets extreme vibration accelerations as
  collision of machine components (spindle, tool,
  machine table) and performs an emergency stop -
  preventing further damage

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Spindle Lifetime Histogram
VCM continuously captures the spindles load,
speed, vibration, and other factors affecting its
condition over its lifetime and combines them
into a single usage factor reflecting the true
condition of the spindle.
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Post-Failure Vibration Analysis
As a "Black Box", VCM stores machine vibration
history for post-failure vibration analysis. VCM
helps in

• Reporting on machine alarms
• Discovering incorrect operating practices
• Minimizing machine warranty costs
• Communicating vibration and alarm information
  through a factory network

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VCMs Competitive Advantages

• PC-based User Interface fully integrated into
  leading CNCs
• Simple user interface requires minimum operator
  effort to run a new part
• Universal solution applicable to any CNC control
  new and old
• Tool-specific monitoring enables protection of
  individual tools
• VCM can operate for each tool

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VCMs Competitive Advantages

• VCM eliminates chatter (vibrations) - thus
  preventing damage to spindle, tools and parts
• VCM can operate in a network under OMATIVE-Pro
  Production Performance Monitoring that enables
  comprehensive reliable machine monitoring and
  supervision
• Continuous vibration monitoring for a whole range
  of processes, incl. Milling, Drilling, Turning,
  Grinding, Broaching Gear Hobbing.