Lösungen – Nordmann Metal Cutting Monitoring

Benefits of our tool monitoring system

Extensive sensor palette for the most divergent measurement values and areas of application. Therefore even difficult monitoring tasks can be solved (e.g. miniature tools, multi-spindle drill heads, machining in hardened material, grinding with the smallest abrasive pencil, machines with many work stations, etc.)
Upgradable as unified system on all machine controls, independent of type and year of construction, whether with or without PC as a work station.
Universal Profibus interface, configurable for all machine controls that can transfer internal driving data to the Profibus
Particularly good monitoring strategy for the recognition of the smallest breakages with turning, drilling and cutting
Wear monitoring basically included in the system without extra charge
Very user-friendly pull down menus, graphic adjustment of the limit values and automatic envelope correction
Development, production, sale, installation and service all from one company
Service worldwide and quick on-the-spot support

Cost-Benefit Analysis of Nordmann Tool Monitoring — Customer Example

Cost, Profit and Savings Factors	Details/Calculation	Costs, Profits and Savings per year
Additional machine running time (break run and in an unmanned shift)	4 hours/day on 250 days/year with a yield of 80 €/hour in an unmanned shift	Additional Profit: 80.000 €
Avoidance of follow-up costs due to tool breakage (defective tools, including on subsequent stations)	Previously 1.500 €/week for 50 weeks/year due to damage to tools, holders and machine parts	Cost Savings: 75.000 €
Prevention of machine fires	Annualized costs of machine fires of 5.000 €/year	Cost Savings: 5.000 €
Avoidance of follow-up costs due to tool breakage (downtime)	2 % more output with a yield of 80 €/hour in two-shift operation (16 hours/day on 250 days/year)	Additional Profit: 6.400 €
Extended tool life	20 % longer service life with tool costs of 90.000 €/year	Cost Savings: 18.000 €
Increase cutting parameters without risk	10 % more output at a yield of 80 €/hour over 16 hours/day on 250 days/year	Additional Profit: 32.000 €
Possibility of using less expensive tools	5 % savings on annual tool cost amounting to 90.000 €/year	Cost Savings: 4.500 €
Measurement curve visualization reveals time-consuming travel distances in slow working feed rates	5 % more output at a yield of 80 €/hour over 16 hours/day on 250 days/year	Additional Profit: 16.000 €
Detection/prevention of short parts by means of control during face turning or by means of workpiece length sensor WLT or IND	Savings on a separate testing station costing 1.500 €/year and/or manual testing requiring 50 man-hours/year at 35 €/man-hour	Cost Savings: 3.250 €
In-process workpiece dimension inspection using friction noise between the test tool and the rapidly rotating surface of the workpiece or tool	Savings on a separate testing station costing 1.500 €/year and/or manual testing requiring 50 man-hours/year at 35 €/man-hour	Cost Savings: 3.250 €
Avoidance of air cuts ("gap control") through cut detection, especially during grinding	5 % more output at a yield of 80 €/hour over 16 hours/day on 250 days/year	Additional Profit: 16.000 €
Additional profit with tool monitoring	Addition of additional profit and cost savings	Total: 259.400 €
Costs of the tool monitoring system	Annual rental fee of 3.500 € for Tool Monitor and sensors	Rental cost: 3.500 €
Costs of operating the tool monitoring system	1 man-hours/week, 50 weeks/year, and 35 €/man-hour for operating the Tool Monitor	Cost: 1.750 €

The savings and additional revenues shown are based on a concrete practical example with verifiable assumptions regarding running times, hourly rates and tool costs.

To enable you to realistically assess the cost-effectiveness for your own machine, we provide you with a calculation template as a PDF, with which you can adjust all relevant parameters individually!

Special features of our tool monitoring system

Special features of the Tool Monitors:

Graphic correction possibility for envelope limits in the area of recurrent, but localized rises in measurement values, in order to avoid repeated limit violations. Using the Nordmann touchscreen you can graphically correct the envelope with a pen (touch pen), i.e. it is drawn. A PC station screen is used to control corrections to the limit values via an arrow that can be moved on the envelope with the arrow buttons. The envelope can be formed like a rubber band separately for its upper and lower limit.
Automatic adjustment of the envelope limit to a recurrent measurement curve outlier, if the user acknowledges this as a false alarm with automatic limit correction.
Gliding envelope limit calculation for monitoring multi-spindle drill heads with regard to the effective power up to a certain number of drills.
Dynamic analysis: Monitoring the waviness of measurement curves in order to recognise individual missing teeth in the cutter and to monitor stepwise changes in power and performance (breakage when turning).
Mathematic measuring: Permits the addition or subtraction of measurement curves. The subtraction of two measurement curves according to their previous logarithmic results in the formation of a relationship, with which the changes in the direction of force can be monitored. The relationship formation is used to monitor internal driving values (feed and spindle values with regard to current, torque or effective power) and permits the monitoring of wear that is independent of the hardness of the material.
High amount of measurement channels: The basic tool monitoring system SEM-Modul is capable of detecting 8 analog and 20 digital measurement channels. It is extendable up to 16 analog channels.
In process dimension control of work pieces and deflection control of tools and work pieces on an acoustic basis with resolution in the µ-field (granted patent Nordmann no. DE19944865B4).

Special features of the sensor portfolio:

Acoustic emission sensor via a cooling lubricant jet from the tool or work piece (granted patent Nordmann no. DE3627796C1). Thus even the smallest tools can be monitored (e.g. drill bit with Ø=0,1mm!), even in multi-spindle drill heads. Very good acoustic sensoring also when grinding, turning, hobbing and forming (hammering) directly from work pieces or tools.
Acoustic emission measuring via rotating and wireless sensors RSA, RSA-2 and RSA-Ring for grinding-, workpiece- and dressing-spindles.
Acoustic emission sensing via wireless SEA-Wireless sensor for fitting to work piece locating fixtures in machining centres or to the capstan head in lathes.
Acoustic emission sensor via a spring steel element directly from work pieces (patented especially for revolving and transfer lines).
Airborne sound microphone LSM-Q or LSM-L in vicinity of tool. Also acts as impact sensor for jet barriers on a coolant lubricant or compressed air operation basis.
Force sensor BDA-Q and BDA-Kralle for rocking lever in multi-spindle automatic lathes with particularly easy installation via only one M5-screw (both patented).
Force measurement on each individual spindle via the measurement of the elastic support of the spindle (for multi-spindle drill heads).
Work piece length sensors BDA-Pilz and WLT for multi-spindle lathes and rotary cycle machines.
Three-phase effective power measurements: Particularly fast reaction and for the smallest tools.
Hydro distance sensor HDS for breakage control of all cutting tools via a cooling lubricant jet which functions as a tool cutter sensor.
Spark-Sensor SPS for turning tool control at high offset oscillations via the spark sensor.
Pyrosensor PYS for control of individual drill bits in multi-spindle drill heads, chipping temperature etc.
Dynamic pressure sensor SDS for breakage control via a cooling lubricant jet or air jet gate, also for miniature drill bits from Ø=0,1mm. Measurement distance of up to 2,5m in machining center. In comparison to the laser there is no need to wait for the cooling lubricant to run off and it is not affected by dirt.
Torque sensor EMS for single spindle and multi-spindle drill heads, as mounting part in the drive screw, in particular for the monitoring of tapping.

Monitoring strategy of the Tool Monitor

The detection of the process irregularities listed above is achieved through the formation of suitable measuring curves which, after they are filtered with various limits, are delimited in accordance to the monitoring task.

As soon as a limit on the measuring curve is violated, an associated relay or optocoupler closes a switch which, that for example, triggers an immediate feed stop, a switchover of the feed speed, the selection of another tool, or the storage of the tool position.

In the following sub-chapters we show you screenshots of the Tool Monitor, where the individual monitoring options are explained in more detail.