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The use of sensors in manufacturing and machining is old news. Monitoring of temperatures, pressure, and speed are used in a variety of applications. The onset of faster, high-precision CNC machining makes new approaches to monitoring a necessity. Once a CAM program has been loaded into a machine the operation must proceed with operators only able to observe. Incorporating CNC sensors for production monitoring provides instant feedback in microseconds, much faster than any human reaction. Monitoring continues to advance in direct proportion to the capabilities of CAM software and machine tools.
Sensors can collect a range of data that alerts machine operators to the status of the machine, the tool, and the part. Some robust systems can stop or adjust during the production process for improved quality and efficiency. A new era of monitoring in the IIoT revolution is moving from physical monitoring to machine learning. An overview of monitoring approaches and benefits demonstrate the advantages for efficient, quality CNC machining and the prospects for the future.
1)Tool Monitoring
The simplest monitoring systems activate a shutdown on tool failure. Although simple, this avoids further production delays and costly repairs. Tools can also be monitored for speed and position. This provides necessary feedback for programmed toolpaths and cutting sequences.
2) Vibration Monitoring
One of the most difficult factors to compensate for in machining is vibration. Advanced machining approaches with shorter tools and high speed, shorter cuts are reducing the impact, but sensors measuring vibration, known as accelerometers, were one of the first monitoring systems that allowed that speed to be maximized. They relay real-time data that helps extend tool life as well as provide more precise cuts.
3) Production Monitoring
Strategically placed sensors can monitor the toolpath, vibration, tolerances, and even material warp during production. Lasers, cameras, and microphones can all be installed to provide real-time data that can be directly compared to simulated CAM modeling. Full monitoring establishes the basis for data management to streamline production.
4) Data Management
“What gets measured gets done. What gets measured and fed back gets done well, what gets rewarded gets repeated.”
Effective data management increases the company’s ROI and productivity. Recorded data, such as power consumption, can help plan even more efficient use of machine tools for various materials. Time stamping identifies machine usage, staff allocation, and exact production times. Data further enables planning for maintenance, timely replacement of tools or other machine parts. Using this data in the physical realm creates greater efficiencies. Effectively pairing data with complimentary software is where some of the benefits begin to challenge what we have known about machining.
5) Benefits
One of the best places for effective data management is the sweet spot where the cutting tool comes in contact with the workpiece. Advances in sensor technology are optimizing tool wear to intelligently alter the toolpath. Other data from the feedback loop between design and production can automatically locate the part and tool for optimum stability during production.
This data management is also making it possible for machine and tool specifications to be fed into simulation software for even more precise modeling and toolpath execution.
The growing intelligence of software will continue to benefit precision machining. New advances in artificial intelligence (AI) and augmented reality (AR) will soon see machines self-correcting during manufacturing. Incorporating CNC sensors for production monitoring is not the end game. New technologies will continue to develop new applications and new markets.