Preventing unpredictable machine breakdowns
Based upon overall machine tool reliability, it was determined maximum benefits could only be derived if the machine tool was striped down and the components individually analysed. To optimise such results the engineers grouped all the components into their respective sub-systems and identified them and their component families according to their respective function. The problem areas were identified and grouped according to: the motion unit (axis movement), process unit (electro-spindle, headstock, tailstock, etc), accessory unit (automatic pallet changer, automatic tool changer) and auxiliary unit (hydraulics and electrical equipment). Therefore this structured breakdown by function enabled the overall machine tool reliability to be considered. With the entire component structure and their elements grouped, measured and analysed, critical events can now be predicted, and work-time problems easily identified and located. This information combined with digital drives within modern machines means it is very easy to install supporting software applications that can optimise prediction of and planning for reliability and availability as well as condition monitoring. The control integrated condition monitoring system is for machine tools that use open Numeric Controls (NCs). Based on the control-internal data it should be able to provide reliable data collection for the whole R&A system. In addition, it will enable a homogenous integration of the monitoring system into the control interface, estimate the remaining lifetimes of internal components and monitor machine tool component states. The end results of this project now enables manufacturers to make the correct decision for maximum reliability and obtain machine and component in-process data, thus heightening efficient maintenance. Hence the gap between tool design and process loads can be closed further still and lead to increased competitiveness and cost savings.
