LEAD FEATURE TOOLING & CYCLE TIME SAVINGS
tool life counter, to reduce administrative workload.
Analysing deviations in the tool life allows potential areas
for optimisation to be identified.
● TS-MDA (machine data analysis) provides the ability to
record the machine production data and save it for further
analysis. Production data includes machine downtime and
the reasons for this. The analysis of this data can enable
large productivity increases.
● TS-QRep (quality documentation) helps with monitoring
and real-time documentation as proof of quality for critical
processes. Special monitoring standards for the
aerospace industry are already provided and other
individual customer requirements can be implemented, as
necessary. These assure a high standard of quality.
● TS-Connect (network functions) allows ToolScope to be
incorporated in a company network and data to be
automatically transferred to a server or network drive. This
guarantees long-term data storage, an automated back-up
function and remote access.
As an overall package, ToolScope consists of hardware,
software and service components that are put together
and customised to meet the needs of specific customers
and machines. The core element is an industrial PC (IPC)
with individually selected evaluation software,
supplemented by on-screen visualisation at the machine
control system (HMI) or, alternatively, via additional
touchscreens. A collision detection unit with a sensor
system option is available. ToolScope must be connected
to the control system over standard interfaces (Profibus/
Profinet) to be able to receive and transmit the machine
data.
ToolScope records the process forces (torques), mainly
through current consumption. Algorithms and statistical
process control are used to process the data, which is
displayed in real time in a torque versus time graph. The
actual signals are used as the basis for setting limits via a
few learning processes. If the limits are exceeded,
different reactions are triggered or initiated, in line with
customer requirements. Long-term data collection and
recording allow tool or machine wear to be observed.
ToolScope automatically adapts the feed rate of the
machine, based on an acquired control variable. ■
Integrating ToolScope & current market use
Lennard Dubrall, product manager ToolScope, says the system can be employed with all types of machines and
processes. “For the system it doesn’t matter whether it is a machining centre or lathe. As a tool manufacturer of
defined edges, we have the most experience in that matter. For example, we have a partnership with Tyrolit, which is a
manufacturer of grinding wheels. The company is using the ToolScope hardware and we have programmed special
monitoring strategies for grinding applications: adaptive dressing and chip removal monitor.
“What is key is that we are able to obtain a good monitoring signal, to which we apply our functions. In general, we
support the Siemens, FANUC and Heidenhain controls, which should be newer then 2004. We plug ToolScope into
these units via common field bus systems like Profibus or Profinet. Besides the connection of the fieldbus system, our
PLC Engineers are able to adapt the logic of the machine control, a so-called PLC/PMC project.”
ToolScope is a well-known process monitoring system, having a pedigree stretching back more than 10 years, and
now has rising awareness in the market. Dubrall says there are more than 1,100 installations across the world, with a
concentration in the automotive sector. A typical field of installation is series production (see other box item, p11),
where for a fuel rail component the outcome was up to 30% savings in tools and a significant cycle time reduction for
both turning and milling applications.
He says that the company sees potential in the aerospace sector, since the requirement for high quality production
is paramount. In this regard, Dubrall highlights two developments. “We have developed two special monitoring
algorithms (GEP11TF12, MTV 548-4). Besides the actual monitoring job, we are able to print a PDF document to
provide full transparency for the proof of quality.” Indeed, there is already a UK installation at an unnamed aerospace
parts maker, he offers.
Collisions can be
addressed in
1 ms, minimising
damage to
machines, tools,
toolholders
fixturing or
expensive parts
themselves
12 July/August 2020 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets
/www.machinery.co.uk