验收快报丨华东知名液压机械企业“TMS刀具监控系统”项目验收
近日，西格数据为华东某知名液压机械高新技术企业部署的“TMS刀具监控系统”项目顺利验收！感谢客户信任和项目团队的辛勤付出，使得客户端能够快速应用TMS无人化刀具监控。该项目的核心目标是实现对加工过程中刀具状态的实时监控，即使在缺少技术人员支持的情况下，系统也能通过精准提示引导工作人员进行刀具更换。
一、客户背景介绍
该客户一直从事液压系统方面的研究开发和生产，是国家高新技术企业，国家三A诚信经营企业，机电部定点设备采购合作企业，服务于全球冶金、煤炭、机械、化工、农业、矿业、石油、航运等行业，主要产品包括液压气动快速接头，阀门，管接头，高压胶管，旋转接头等；先后通过ISO9001质量管理体系认证，TUV产品质量认证，CE认证，公司一直坚持“诚信创发展，服务以致远”的价值观，秉承“让客户成为朋友，让员工成为家人”的企业文化，致力于实现“做中国快速接头单品冠军，让不一样的中国快速接头走向世界”的公司愿景，目前公司产品远销全球各地，获得众多客户一致好评。
（1）车间情况：客户现场的刀具主要是钻头、车刀、铣刀、外径精车等多种刀具，设备是车铣复合（发那科系统) ；
（2）客户痛点：白班产能受限，迫切需要启动夜班生产以提升整体产能，然而，夜班期间缺乏技术人员的支持，急需引入一套先进的无人化刀具监控解决这一难题；
基于上述客户痛点，西格数据实施交付团队为客户快速安装SIGER TMS无人化刀具监控系统,实时监测主轴负载，并针对刀具崩刃与断刀提供及时的监控预警，实现自动化停机控制，引导工作人员进行刀具更换，解决了夜班无技术人员支持的问题，帮助企业大大提升整体生产的效率和产能。
二、项目部署
2.1刀具监控系统-监控原理图
刀具监控系统（Tool Monitoring System，TMS）是一种针对精密加工过程中刀具状态监控和管理的解决方案，该系统通过边缘传感器收集数据，并利用智能算法分析这些数据，以实时监控刀具状态，断刀、崩刃智能诊断，并实现停机控制，真正意义上做到预测刀具寿命，帮助企业在生产过程中对停机换刀的处理更加游刃有余，避免因崩刃断刀而造成的设备损坏与产品质量损失！
2.2刀具监控系统-软硬件配置
三、数据验证
以上数据为TMS对车刀正常加工、崩刃加工进行了测试验证，从加工负载曲线可以明显进行区分识别，刀具在加工过程中实时数据超过TMS包络上限时立即报警停机达到预期。
以上数据为TMS对铣刀正常加工、断刀加工进行了测试验证，从加工负载曲线可以明显进行区分识别，刀具在加工过程中实时数据超过TMS包络上限时立即报警停机达到预期。
验收报告：
应用效果：
近日，在常规的机加工流程中，刀具状态的传统监测方法存在局限性，往往难以实时直观地掌握刀具状况。现场操作通常依赖于固定的刀具寿命管理或依赖技术人员的经验来预估刀具寿命，以此降低因加工异常导致的刀具和机床等固定资产的损失。
因此，SIGER TMS E3系统的部署改变这一现状，基于异常刀具标定包络线样本，设定阈值上下线，帮助企业完成刀具崩刃&断刀监测，防止撞机减少不良品发生，同时，该系统解决了夜班时段无技术人员支持的情况下，通过预警提示引导工作人员完成刀具更换，确保了生产的连续性和效率。经过现场的实际操作演示和使用培训，项目获得客户高度认可，成功验收！
快速了解SIGER TMS刀具监测系统
西格数据刀具监控系统（Tool Monitoring System，TMS）是针对精密加工行业在刀具使用过程中的难点为客户量身打造的一款刀具状态监测软件，通过采集主轴电流（负载）等30维度+数据信号，结合自学习算法和行业多年经验数据沉淀，实现刀具磨损、崩刃、断刀的精准监控，并自动报警停机，避免因刀具导致的批量报废、质量损失！有效提高刀具寿命30%以上！
西格数据刀具监控系统适配范围:
■ 适用机床类型：加工中心、龙门、车床、车铣复合等多种机床切削场景；
■ 适用加工工艺：大批量重复加工、大批量嵌套工艺加工、小批量加工、无NC场景等多种工艺类型；
■ 适用加工方式：车削加工|铣削加工|钻孔|攻丝|齿面加工|曲面等多种粗加工、精加工场景（加工量不低于10丝）
如您对西格数据的产品感兴趣，可以拨打电话：189 6235 3927（微信同号），也可以留下您的需求、电话和公司名称，我们会第一时间与您联系。
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Acceptance Report | Acceptance of the "Tool Monitoring System" Project by a Renowned Hydraulic Machinery Enterprise in East China
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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
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.
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;
■ Applicable machining methods: turning machining | milling machining | drilling | tapping | tooth surface machining | curved surface and other rough and precision machining scenarios (machining quantity not less than 10 threads)
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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