Benefits in the handling

PROCESS MONITORING – The major order from a notable German automotive supplier included, that Sema machine company had to equip the ordered 21 revolving transfer machines with the process monitoring Toolinspect from MCU.This are machine tools of the special kind. A major notable German automotive supplier ordered 21 revolving transfer machines RTA Tera 100 Planet for the processing of brake callipers from Sema. These revolving transfer machines have six stations, 44 NC axes and a total system weight of 54 tons.

Beneath these machines for heavy cutting, the specification sheet included also the integration of the process monitoring systems Toolinspect from MCU. A demand, which Karl-Heinz Pflügl, project manager at Sema Maschinenbau GmbH, nowadays assesses positively: “The use of these systems was interesting for us, because due to customers’ wishes we only used products from MCU’s market competitors until then.” That was not always easy, because these systems had mainly the disadvantages that they were very maintenance intensive and had to be adapted permanently anew after process variations. “But in Toolinspect we see a real alternative. The handling is easy, the surface and the definition of the cycles in the NC program is very clear”, Pflügl adds.

Beneath these advantages in the handling, in Traunkirchen Toolinspect convinces also with the fact, that the standard components for the Simatic-S7-Software from Siemens and the standard cycles for the NC program are included by MCU. In addition from the Software of Toolinspect a data export for diagnosis purposes can be performed. This file can be used for process optimizations. Another positive aspect is, that with this, two different monitoring strategies are possible. On the one hand this is the monitoring of the torque via the time, on the other hand the monitoring of the processing forces via the path of the feed axis.

Curve shape monitoring ( Left without optimized Milling / Right optimized with Speed)

Contrarily David Schacherleitner, sales manager for machine tools at Sema, does not see the advantages that much in the detail but much more in the handling of the process monitoring: “In general I like the idea of the process monitoring, especially the idea of the axis monitoring.” However it is always a matter of definition what is monitored and how a system can be integrated. “Therefore we were not mad if we did not have to offer such systems so far. But for us it was surprising, how easy Toolinspect could be integrated regarding PLC and NC program.” MCU had the PLC files pre-assembled and developed structures together with Siemens. Now, until 2018, 21 revolving transfer machines including Toolinspect are ordered, but the first ones are already delivered. All tools are monitored – from the driller diameter 3 to 12 mm up to the side milling cutter with 280 mm diameter. Actually it is about a double treatment with tools on three levels (five tool pairs are monitored at the same time). That is possible, because Toolinspect works with two modules, hence ten channels. Such a use can be realized even for combination tools, because MCU counts on the curve shape monitoring. This means, every processing creates certain curves. If this curve form is defined, suitable limits can be set.

Interfaces clarified

Such a major order can only be realized if all participants develop solutions together. That also applies for Traunkirchen. MCU, Sema and Siemens discussed the interfaces and the machine performance and defined the structure. Within only two months the commissioning was carried out. For Uwe Schr?ter, managing director of MCU, this short period is nothing special: “In the development of our systems we considered a high flexibility, so that it can be integrated fast into different control environments. This allows us to work also under Linux or Windows. But in this concrete case the client is one of our customers since many years and invests in about 100 systems every year.”

For Sema the first use of Toolinspect seems not only consistently positive but also very interesting as the functionality and the easy integration also apply for all the controls which Sema is using – including Siemens, Fanuc and also Bosch-Rexroth. Also Toolinspect is available in 21 languages and therefore well equipped for the international use.

1988 founded, Sema currently employs 195 employees and focuses in the development, manufacturing and assembly of customized machines for the serial production and special treatment. Sema operates in the branches automotive, energy, logistics and transport, building technology such as industry.