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

Recently, SIGER successfully accepted the "TMS Tool Monitoring System" project deployed for a well-known domestic new energy enterprise! Thank you for the trust of the client and the hard work of the project team, which enabled the client to quickly apply TMS unmanned tool monitoring. The core objective of this project is to achieve real-time monitoring of tool status during the machining process, with the aim of preventing batch scrap of products caused by tool breakage or chipping. At the same time, even in the absence of technical personnel at night, the system can guide operators to replace tools in a timely manner through accurate prompts, thereby ensuring the improvement of production efficiency and product quality for enterprises.

1. Customer background introduction:

The client is a leading enterprise specializing in aluminum production and processing, with business involving new product development, product processing, and import and export trade. The company is equipped with a complete production line, covering key processes such as melting and casting, profile extrusion, anodizing, electrophoretic coating, and powder coating. In terms of precision machining, we provide cutting, punching, bending, CNC machining, welding and other services, committed to providing customers with comprehensive support from aluminum product development, product design, alloy selection, mold manufacturing, surface treatment to secondary CNC machining, packaging design and other aspects. To meet market demand, various products have been developed to cater to different markets, including automotive aluminum components, electronic accessories, solar module brackets, LED frames, heat sinks, and various industrial products. Our business covers various fields of the new energy industry chain. The product enjoys a high reputation in both domestic and international markets, with 80% of the products exported to international high-end markets such as the United States, Europe, Japan, South Korea, Singapore, Vietnam, and Thailand. By establishing its own marketing network, the enterprise has become a well-known brand in the domestic new energy industry.

2.Project Introduction

Customer Status Before Using the 'Tool Monitoring System'

(1) Workshop situation: The main cutting tools on the customer's site are drill bits and milling cutters, and the equipment is single spindle machining centers (brother machines and Haas machine tools);

(2) Customer pain points: Without technical personnel on duty during nighttime production, production capacity is limited. At the same time, batch scrapping of products caused by tool breakage or breakage seriously affects production efficiency and cost control.

Based on the customer pain points mentioned above, the SIGER implementation and delivery team quickly installed the SIGER unmanned tool monitoring system for the customer to monitor the spindle load in real time.

After deploying SIGER "tool monitoring system" - benefit improvement

3.Project deployment

3.1Tool Monitoring System - Monitoring Schematic Diagram

The tool monitoring system is a solution for monitoring and managing tool status in precision machining processes. The system collects data through edge sensors and uses intelligent algorithms to analyze this data, in order to monitor tool status in real time, diagnose tool breakage and blade 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 blade breakage!

3.2 Tool Monitoring System - Software and Hardware Configuration

  

4. Data validation

Verification of the cutting effect of drill bits:

The above data is a test verification of TMS for normal machining and tool breakage machining of drill bits. 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 chipping effect

 

The above data is a test verification of TMS for normal machining and chipping 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 Machine 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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Official Contact Info:

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