IIOT SOLUTIONS » 1. CNC & INDUSTRY 4.0
With this project, which can be considered within Industry 4.0, the key data of the machines by remote access is collected in a center and this data is converted into a report.
With "Kapasitematik", a remote monitoring and efficiency reporting system, CNC users and businesses can measure their existing machines and see historical trend analyses.
In normal circumstances, it is possible to complete and follow this type of work, which can be a problem for a business both in terms of cost and time, with a single click of Kapasitematik.
1.2.1 SPECIAL MACRO PROGRAM STUDIES FOR YOUR COMPANY
While working in your machining center, your approach to tool life management is “cut or break”. Tool breakage is a concern, but you also need to implement a process that does not “disrupt” your productivity. In general, it is relied upon to keep spare tools at hand. This means you have to stop the machine to replace the tool.
As a result, it means stopping production by stopping the spindle. However, there is a way to switch to a new tool while your CNC machine is running, and you can plan it with real tool life management.
Wattpilote, which can be used in all kinds of mass-produced machines, is easy to use, sensitive and has a very high benefit/cost ratio.
Main capabilities of the system;
- Detects tool breaks,
- Detects faulty-broken tool processing,
- Detects tool wear,
- Detects material-casting errors,
- Guides you in determining your processing method.
With Wattpilote tool monitoring system;
- Increases tooling efficiency and reduces costs,
- Prevention of tool breakage,
- Minimizes operator errors,
- Reduce your quality control costs while providing 100% control at the points you are monitoring
- Optimize your machining time and improve machining quality
1.3 MEASURING PRODUCTION VARIABLES & QUALITY WORKPIECE MANUFACTURING
The biggest advantage when measurements are made during manufacturing is that the problem can be detected before the product is taken from the manufacturing environment, so that revision can be applied in the final process to be performed on the part. In summary, the amount of scrap can be reduced by positive intervention in manufacturing.
Since this process is carried out without removing the part from the machine, it is also prevented to re-import and adjust the part which causes high cost.
Particularly in the aerospace industry, time, cost and energy can be saved considerably for the repositioning of large complex parts, large molded parts in the automotive industry.Since the measurement will be on the machine tool during the process by determining the correction values for the manufacturing and applying them to the manufacturing, it is possible to make these corrections immediately with the data sent to the control of the machine tool.
Since the measurement process is done on the machine where the product is processed, it is possible to make very sensitive interventions to the production process by doing this several times in different ranks. Since it is possible to use the production machine as a measuring machine, it is possible to make and report the final measurement of the product instead of performing a separate measurement process. This gives a great advantage, especially for large and heavy parts that are very difficult to transport.
Machine tool performance, during production, temperature, vibration, etc. such changes due to external factors. It is possible to check machine tool performance with measurement during the process and to make the necessary interventions in time. It is possible to complete and follow this type of work with a single button with capacitance, which may be a problem in terms of cost as well as time.
1.4 CNC & ERP INTEGRATION
In SAP Production Integration and Intelligence (SAP MII) projects, some functional data is obtained from CNC machines and NC systems. This data;
- Data collection,
- Number of workpieces,
- Program numarası,
- Program number,
- Alarm conditions,
- Operation time,
- Industry 4.0 provides support in the transition process for transparent monitoring of machines such as downtime and ensuring flexibility and adaptability in production.
IIOT SOLUTIONS » 2. MAINTENANCE & INDUSTRY 4.0
Predictive maintenance is to understand the health of the machine by looking at indicators with ”check-up" and to make corrective interventions accordingly. To understand the health of the machines, various parameters; vibration, temperature, humidity, metal particles in machine oil, pressure, noise, electrical current values are measured. By examining the measured data, it can be understood where there is a possibility of failure in the machine.
* Equipment Cost; instead of replacing all equipment due to a critical failure, reducing the cost of materials and labor required by pre-failure maintenance.
* Labor Cost; as the data is strengthened, only the replacement of the materials that need to be changed or maintained.
* Machine Running Time; protecting your business from “unplanned stops” by shaping the postures as “planned stops" only.
* Safety; by anticipating potential problems with Predictive Maintenance, a safer environment is created for employees.
* Labor Time; reduction of the time required for the detection and correction.
IIOT SOLUTIONS » 3. SERVICE & INDUSTRY 4.0 | Vibration (TAP) Test
Experienced CNC Operators face similar evidence that the selected parameters are not ideal or when faced with possible cuttings in a low-performance milling, changing the certain aspects of process, reducing the combination of specific parameters, cutting depth, speed and feed rate, or even reducing the tool length.
However, in such a case, you will not be able to operate your full-speed machine that you have purchased by making large investments and will be wasted. It can also be a solution in high-speed operations, rather than downloading parameters. For this purpose, vibration analysis which determines cutting conditions with more scientific data rather than operator experience is in front of us as the right solution.
With VIBRATION (TAP) TEST;
Speed is the first factor that determines machining performance.
Knowing the best feedrates will help increase cutting depth and cutting width.
A good cutting speed also provides better surface quality and increases tool life, spindle life and sawdust removal rates.