Monitoring Strategies
Benefit of the process monitoring with Process Control Tools
All strategies in the PCT Module work “in-process,” meaning that the measurement signals are analyzed and evaluated during processing. This allows for immediate response to the actual status of the process and adjustment of production during the ongoing process.
The parameters of the monitoring strategies are automatically set using a learning cycle, so the operator does not have to perform time-consuming settings. However, with the PCT Monitor app, they have access to it at any time and can gain insight into the progress of process monitoring.
PRV - Process Visualization
- Recording process cycle and measurement signal, without monitoring
- Display process data on the PCT Monitor
Example application:
No monitoring executed. By analyzing the data, the right monitoring strategy can be selected.
ASS - First Cut Sensor, self-adjusting
- Automatic setting of the threshold value with a learning cycle
- Reliable first cut detection even when cooling lubricant is used
- Function for detecting the first contact between the grinding wheel and the workpiece in case of excessive material allowance.
Example application:
To reduce air grinding, and switching directly to the machining process.
TOM - Tool Monitoring
- Measurement signal and integral of a cast component are learned with a learning cycle
- Monitoring the tool wear based on a cast component and mean value deviation, with status signal at cycle stop
- Detecting tool break immediately, already during process cycles
- Automated missing tool identification, with status signal at cycle stop
Example application:
For tool monitoring on turning, milling and drilling machines.
HUK - Envelope Curve
- The measurement signal of a cast component is learned with a learning cycle
- Monitoring the process cycles that should recur in a consistent way
- Deviations (increase or decrease) are monitored with an adjustable response time
Example application:
To detect exceeding or underrunning of an envelope curve during process monitoring.
INT - Integral Sensor
- Integral area of a cast component is learned with a learning cycle
- Monitoring the deviations in reference to the cast component especially in the case of strong fluctuations in the measurement signal
Example application:
To monitor minimum and/or maximum stock removal.
SWT - Threshold Time Sensor
- Evaluation of a fixed threshold exceeding
- The process is considered correct if the measurement signal remains above the defined threshold for a specified duration
- Used to monitor the minimum and/or maximum machining process
Example application:
To ensure that the workpiece has undergone at least the minimum required processing.
TCH - Touch Dressing
- Dressing tool approaches the grinding wheel stroke by stroke to detect first contact
- Monitoring of the grinding wheel contour to ensure dimensional accuracy
- High process reliability through the monitoring of the entire dressing process
- Thermal displacements of the machine have no longer effect on the dressing amount
Example application:
Reducing significantly grinding wheel costs in order to decrease touch dressing strokes.
SIS - Segmented Integral Sensor
- Grinding wheel contour of a cast component is learned with a learning cycle
- Detection of the slightest defects on the tool and monitoring the dimensional accuracy
- Detection of the minimum and maximum amplitudes during dressing
Example application:
For precise monitoring of previously learned segments during the dressing process.
REF - Reference signal
- Activate strategy with an additional job instance
- Visualization of a learned process cycle as a grey signal in the background
Example application:
For the visual detection of deviations.
