Acceptance Report | Acceptance of the "Tool Monitoring System" Project by a Renowned Hydraulic Machinery Enterprise in East China

Recently, SIGER quickly completed the acceptance of the "TMS Tool Monitoring System" for a well-known power device enterprise in South China. The project took only 7 days from customer consultation to formal acceptance, demonstrating SIGER's service capability of delivering at lightning speed! Thank you for the customer's trust and the hard work of each employee, which enables the client to quickly apply TMS unmanned tool monitoring.

1. Customer background introduction:

The customer has been engaged in research, development, and production of hydraulic systems. It is a national high-tech enterprise, a national 3A integrity management enterprise, and a designated equipment procurement cooperation enterprise of the Ministry of Mechanical and Electrical Engineering. It serves industries such as metallurgy, coal, machinery, chemical industry, agriculture, mining, petroleum, and shipping worldwide. Its main products include hydraulic and pneumatic quick couplings, valves, pipe fittings, high-pressure rubber hoses, rotary couplings, etc; The company has successively passed ISO9001 quality management system certification, TUV product quality certification, and CE certification. It has always adhered to the values of "integrity creates development, service leads to long-term success" and upheld the corporate culture of "making customers friends and employees family". It is committed to realizing the company's vision of "becoming the champion of Chinese quick connector products and bringing different Chinese quick connectors to the world". Currently, the company's products are exported to various parts of the world and have received unanimous praise from many customers.

(1) Workshop situation: The main cutting tools on the customer's site are drill bits, turning tools, milling cutters, outer diameter precision turning tools, etc. The equipment is a combination of turning and milling (Fanuc system);

(2) Customer pain point: Limited production capacity during day shift, urgent need to initiate night shift production to improve overall production capacity. However, there is a lack of technical support during night shift, and an advanced unmanned tool monitoring system is urgently needed to solve this problem;

Based on the customer pain points mentioned above, the SIGER implementation delivery team quickly installed the SIGER unmanned tool monitoring system for the customer, which monitors the spindle load in real time and provides timely monitoring warnings for tool breakage and breakage. It realizes automated shutdown control, guides staff to replace tools, solves the problem of no technical support for night shifts, and greatly improves the overall production efficiency and capacity of the enterprise.

2. Project deployment

2.1 Tool Monitoring System - Monitoring Schematic Diagram

The Tool Monitoring System (TMS) is a solution for monitoring and managing tool status in precision machining processes. The system collects data through edge sensors and analyzes this data using intelligent algorithms to monitor tool status in real time, diagnose tool breakage and edge breakage intelligently, and achieve shutdown control. It truly predicts tool life and helps enterprises handle shutdown and tool replacement more easily in the production process, avoiding equipment damage and product quality loss caused by blade breakage and edge breakage!

2.2 Tool Monitoring System - Software and Hardware Configuration

3.Data validation

Verification of tool breakage effect:

The above data is a test verification of TMS for normal machining and chipping machining of cutting tools. It can be clearly distinguished and identified from the machining load curve. When the real-time data of the tool exceeds the TMS envelope upper limit during the machining process, it immediately alarms and stops, achieving the expected results.

Verification of milling cutter cutting effect:

The above data is a test verification of TMS for normal machining and tool breakage machining of milling cutters. It can be clearly distinguished and identified from the machining load curve. When the real-time data of the tool exceeds the TMS envelope upper limit during the machining process, it immediately alarms and stops, achieving the expected results.

Acceptance report:

Application effect:

In the conventional machining process, the traditional monitoring methods for tool status have limitations and are often difficult to grasp the tool condition in real-time and intuitively. On site operations usually rely on fixed tool life management or rely on the experience of technical personnel to estimate tool life, in order to reduce the loss of fixed assets such as tools and machine tools caused by machining abnormalities.

Therefore, the deployment of SIGER TMS E3 system has changed this situation. Based on abnormal tool calibration envelope samples, threshold up and down lines are set to help enterprises complete tool breakage and breakage monitoring, prevent collisions and reduce the occurrence of defective products. At the same time, the system solves the problem of no technical support during night shifts, guiding workers to complete tool replacement through warning prompts, ensuring production continuity and efficiency. After on-site practical operation demonstration and usage training, the project has been highly recognized by the customer and successfully accepted!

Quickly understand SIGER tool monitoring system

SIGER Tool Monitoring System (TMS) is a tool condition monitoring software tailored for customers in the precision machining industry to address the difficulties in tool use. By collecting 30 dimensional+data signals such as spindle current (load), combined with self-learning algorithms and years of industry experience data accumulation, it achieves accurate monitoring of tool wear, chipping, and breakage, and automatically alarms and shuts down to avoid batch scrap and quality loss caused by tools! Effectively increase tool life by over 30%!

Scope of adaptation of SIGER tool monitoring system:

■ Applicable machine tool types: machining centers, gantry, lathes, turning milling composite and other machine tool cutting scenarios;

In order to improve

■ Applicable processing techniques: multiple types of processes such as large-scale repetitive processing, large-scale nested processing, small-scale processing, and no NC scenarios;

If you are interested in SIGER products, you can contact us by phone or email, or submit your requirements by leaving a message, and we will arrange personnel to contact you as soon as possible.

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