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Real-Time Machine Shop Productivity


Real-Time Machine Shop Productivity & Optimization Solutions * * * * * * * * * * * * * * * Vibration Control Monitor (VCM) VCM continuously monitors machine tool ... – PowerPoint PPT presentation

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Title: Real-Time Machine Shop Productivity

Real-Time Machine Shop Productivity
Optimization Solutions
Vibration Control Monitor (VCM)
  • VCM continuously monitors machine tool vibrations
    during machining
  • VCM analyzes the vibration data in real-time and
    issues warnings and/or stops the machine if
    unacceptable vibration conditions occur thereby
    preventing pending failures
  • VCM provides information about potential failures
    and can call for preventive action based on the
    machines vibration signature analysis

VCM Main Features
  • Machine Vibration Signature Analysis
  • Simultaneous Monitoring of up to 3 Machine
  • Vibration Data Collection, Storage And
  • Lifetime Utilization Histogram Representing
    Machine Condition History
  • "Black Box" Post-Failure Vibration Analysis
  • Tool-Specific Vibration Monitoring
  • Tool Part Run Out Detection
  • Fast Response Collision Detection

VCM in Machine Environment
VCM Configuration
  • Accelerometer(s) installed on vibration-prone
    machine location(s)
  • VCM Data Acquisition Hardware
  • VCM HMI can be integrated into
  • Stand-alone PC
  • Siemens Sinumerik 840D
  • OKUMA OSP-P200

Overall Machine Vibration Monitoring
  • VCM can continuously monitor the Overall
    machine, guarding against excessive vibrations in
    every machining operation in two ways
  • Time-domain - VCM continuously measures a
    broadband of vibration acceleration, velocity,
    and displacement - according to the ISO 10816
  • Frequency-domain - VCM triggers alerts or alarms
    if the vibration exceeds its permissible band
    limits across the frequency spectrum

Time-Domain Vibration Analysis
  • VCM analyzes the vibrations in Time-domain in
    three configurable frequency ranges
  • Low frequency band - with adjustable bandwidth,
    to determine the vibration displacement level
    (peak to peak) within this band.
  • Medium frequency band - with adjustable
    bandwidth, to determine the vibration velocity
    level (RMS) within this band.
  • High frequency band - with adjustable bandwidth
    to determine the vibration acceleration level
    (RMS) in this band.

Frequency-Domain Vibration Analysis
  • VCM uses Fast Fourier Transform (FFT) processing
  • Real-time frequency-domain analysis
  • Vibration signature recording and analysis
  • In real-time frequency-domain analysis, VCM can
    analyze up to 10 configurable narrow bands.

The bands may be selected based upon operating
conditions and expected fault vibration
Tool-Specific Vibration Monitoring
By distinguishing between vibration behaviors of
various tools, VCM can automatically prevent
dangerous vibration conditions for each
tool. Tool-specific vibration monitoring is
carried out in both time and frequency domains.
Time-domain analysis determines the overall
vibration velocity level only within the medium
frequency band.
Tool-Specific Vibration Monitoring Setup
Vibration Signature Analysis
VCM enables preventive action to be taken based
on a comparison of
  • Machines current vibration signature
  • Machines reference vibration signature in
    healthy condition

The deviation is limited by an envelope around
machines reference signature.
V-Signature Recording Storage
Direct NC program access to V-Signature recording
function. Start command initiates the recording
process. It is forced to stop either by achieving
required accuracy or by the Stop command. A
V-Signature file is generated and saved
VCMs Collision Detection
  • VCM interprets extreme vibration accelerations as
    collision of machine components (spindle, tool,
    machine table) and performs an emergency stop -
    preventing further damage

Spindle Lifetime Histogram
VCM continuously captures the spindles load,
speed, vibration, and other factors affecting its
condition over its lifetime and combines them
into a single usage factor reflecting the true
condition of the spindle.
Post-Failure Vibration Analysis
As a "Black Box", VCM stores machine vibration
history for post-failure vibration analysis. VCM
helps in
  • Reporting on machine alarms
  • Discovering incorrect operating practices
  • Minimizing machine warranty costs
  • Communicating vibration and alarm information
    through a factory network

VCMs Competitive Advantages
  • PC-based User Interface fully integrated into
    leading CNCs
  • Simple user interface requires minimum operator
    effort to run a new part
  • Universal solution applicable to any CNC control
    new and old
  • Tool-specific monitoring enables protection of
    individual tools
  • VCM can operate for each tool

VCMs Competitive Advantages
  • VCM eliminates chatter (vibrations) - thus
    preventing damage to spindle, tools and parts
  • VCM can operate in a network under OMATIVE-Pro
    Production Performance Monitoring that enables
    comprehensive reliable machine monitoring and
  • Continuous vibration monitoring for a whole range
    of processes, incl. Milling, Drilling, Turning,
    Grinding, Broaching Gear Hobbing.