Acceptance Report | Acceptance Test of "Tool Monitoring System" Project for a Well-known Domestic Independent Brand Machine Tool Manufacturer

Recently, SIGER Data successfully completed the acceptance testing of its "Tool Monitoring System" project for a well-known domestic independent brand machine tool manufacturer in Guangdong, China! We thank the client for their trust and the project team for their hard work, enabling the client to quickly implement TMS unmanned tool monitoring. The core objective of this project was to equip end-users with an advanced tool monitoring system, enabling real-time, accurate monitoring and early warning of tool status during production. This effectively avoids the risk of batch product scrap due to tool breakage or chipping, safeguarding the company's production efficiency and product quality, ultimately achieving a win-win situation for both the company and the client.

1. Customer background introduction:

This client is a CNC equipment manufacturer with over 20 years of professional experience. The company integrates R&D, production, sales, and service, focusing on the manufacturing of high-quality CNC deep hole drilling machines, gantry machining centers, vertical machining centers, and other related products. It has a technical team of over 120 people and an after-sales service network covering multiple provinces, with offices in Beijing, Shanghai, Jiangsu, and other locations. The company's products are widely used in mold manufacturing, automotive parts, precision electronics, aerospace, medical devices, and many other fields. Adhering to the principle of integrity and mutual benefit, the company is committed to working hand in hand with its customers to create a better future for the manufacturing industry.

2.Project Introduction

Customer Status Before Using the 'Tool Monitoring System'

(1) Workshop Situation: The customer's on-site tools are mainly drill bits and milling cutters, and the equipment is a machining center;

(2) Customer Pain Points: Facing increasingly fierce market competition and higher requirements from end customers for machine tool performance, especially the demand for real-time tool status monitoring, the customer's pain points are particularly prominent;

Based on the above customer pain points, SIGER Data's implementation and delivery team quickly installed the SIGER TMS unmanned tool monitoring system for the customer to monitor 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

Drill bit breakage effect verification:

The above data represents the test verification of the Tool Monitoring System for normal drill bit processing and tool breakage processing. The processing load curve clearly distinguishes and identifies the differences. When the real-time data of the tool exceeds the upper limit of the TMS envelope during processing, an alarm is immediately triggered and the machine is stopped, achieving the expected result.

Milling cutter breakage effect verification:

 

The above data represents the test verification of the tool monitoring system for normal milling and tool breakage machining. The machining load curve clearly distinguishes between them. When the real-time data of the tool exceeds the upper limit of the TMS envelope during machining, an alarm is immediately triggered and the machine is stopped, achieving the expected result.

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:

Email: marketing@siger-data.com

WhatsApp：+86 189 6235 3927

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