Ernst Kulli
GIORNATA DI STUDIO SU UTILIZZO DI SENSORI PER IL MONITORAGGIO DI
MANDRINI PER FRESATURA E RETTIFICA
Usage of sensors in the spindles forhigh performance cutting and precision machining
State of art and new technology
Ernst Kulli
Contents
1. Introduction
2. Spindle integrated sensor
3. Case study of high performance cutting
a. SmartVision
b. SmartDrive
4. Case study of precision machining
a. DMD
b. Shaft cooling
Ernst Kulli
Fischer AG Precison Spindles
- Founded 1939- In the second generation of family ownership
- Location Herzogenbuchsee- 170 Employees
Fischer Precise Group: 3 Brands 7 Locations
Ernst Kulli
Rotation
The name stands for
PRECISE, FAST and POWERFUL rotation
~ 4000 BC.
Ernst Kulli
Quo vadis?
SpeedPrecision Power / Torque
High Power
High Torque
Precision parts
Surfaces
Grinding
Small tools
Ernst Kulli
Bearing
Air bearingBall bearing Hydrostatic Magnet
StaticCompressed air is introducedDynamicAir cushion is built up by the movement itself
Angular contact ball bearingsCylinder roller bearingsand others
StaticLiquid is introduced underpressureDynamicPressure in the fluid buildsup by the pumping action of the two part surface
Contact freeBearing forces isgenerated by controlledelectromagnets
Ernst Kulli
Contents
1. Introduction
2. Spindle integrated sensors
3. Case study of high performance cutting
a. SmartVision
b. SmartDrive
4. Case study of precision machining
a. DMD
b. Shaft cooling
Ernst Kulli
SensorsMotor temperature
Speed
Axial position of interface
Current
Bearing temperature
Vibration level
Number of tool changes
Shaft angle positionForce flow of bearings
Structureacoustic noise
Leckage
Flow rate
Voltage
Ernst Kulli
Sensors
Visualize the condition of the spindle
Records the measured datas
Analysis exceeded warning levels
Registered alarms
Allows to create reports
Safe operation of spindle
Optimization of the machining process
Smart Vision
Ernst Kulli
0
2
4
6
8
1 0
1 2
1 4
2 0 0 0 0 2 1 0 0 0 2 2 0 0 0 2 3 0 0 0 2 4 0 0 0 2 5 0 0 0 2 6 0 0 0 2 7 0 0 0 2 8 0 0 0 2 9 0 0 0 3 0 0 0 0D re h z a h l [1 /m in ]
Schn
itttie
fe, a
p [m
m]
s ta b ile r S ch n itt R a tte rn E xp e rim e n te lle S ta b ilit ts k a rte
F r s e r N r. 7 9 6 8 5 7 1 , D 1 6 lg e s = 1 6 6 ,5 m m , la = 7 5 ,5 m m2 S ch n e id e n , V o llh a rtm e ta llV o lln u t, fz = 0 ,1 8 m m
0
2
4
6
8
1 0
1 2
1 4
2 3 0 0 0 2 4 0 0 0 2 5 0 0 0 2 6 0 0 0 2 7 0 0 0 2 8 0 0 0 2 9 0 0 0 3 0 0 0 0D re h z a h l [1 /m in ]
Schn
itttie
fe a p
[m
m]
F r se r 8 6 2 0 4 5 2 , D 1 6 lge s = 1 3 9 m m , la = 4 8 m m 2 S c h n e id e n , V o llh a rtm e ta ll V o lln u t, fz = 0 ,1 8 m m
s ta b ile r S c h n itt R a tte rn E xp e r im e n te lle S ta b ilit ts k a rte
Itotal = 139 mm
Ia = 48 mm
Itotal = 166.5 mm
Ia = 75.5 mm
Sensors
Ernst Kulli
Forc
e [a.
u.]
Time [a.u.]
Machining forces
5 revolutions
Sensors
Ernst Kulli
SmartVision ReportCustomer send his recorded SmartVision Data backfor analysis by Fischer Engineers.
You will get back an analysis of: Productivity of the machine
Spindle power and torque utilization
Spindle speed utilization
Observations by experienced spindle experts
Recommendations for improving spindle reliability
Ernst Kulli
Contents
1. Introduction
2. Spindle integrated sensor
3. Case study of high performance cutting
a. SmartVision
b. SmartDrive
4. Case study of precision machining
a. DMD
b. Shaft cooling
Ernst Kulli
High Power Milling
Example: Aeronautical structure partsWith spindle power of over 150 kW material removal rate of > 15 l/min are achievable.
Fischer converterfor high power
MFW-2320/30100 kW, 48 Nm S1
MFW-2715/20150 kW, 96 Nm S1
Ernst Kulli
High Torque Milling
Example: Structure parts for energygenerationHigh torque for roughing and high speed forfinishing are necessary to mill difficultmachinable materials with long tools
MFW-2702/08445 Nm, 93 kW S1
MFW-2801/16198 Nm, 28 kW S1
Ernst Kulli
SmartDriveStrong
Current up to 300 Aeff,sufficient for spindle power of 200 kW
Fast Special modulation method up to
20 kHz: high torque and high speed in combination
Current control loop cycle time 2 s Sensor Signal processing, including
recording in 0.2 ms cycle time[PLC Function]
Intelligent Design One connection for all Spindle Sensors Spindle Electronic on Board PC integrated for monitoring of spindle sensors
Ernst Kulli
SmartDrive Process AnalysisView through the Spindle
Process Analysis of Speed Torque Power Vibration at the Cutting Edge
Integrated Oscilloscope Highest Resolution Detailed Information
Communication to CNC Control Exceeding of limit values Quick Signal variation during processing Envelope monitoring or Teach-in Cycle
to optimise the Cutting Process
Ernst Kulli
Contents
1. Introduction
2. Spindle integrated sensors
3. Case study of high performance cutting
a. SmartVision
b. SmartDrive
4. Case study of precison milling
a. DMD
b. Shaft cooling nano
Ernst Kulli
Thermal constant process condition
Shaft cooling
Benefits1. Shortening the time untilsaturation of temperature
Time reduction -80%
Time
Spin
dle
tem
pera
ture
Without shaft cooling
Shaft cooling
Ernst Kulli
Thermal constant process condition
Shaft cooling
Benefits2. Reduction of shaft elongation
Zeit
Without shaft cooling
Shaft cooling
Dilatation -70%
Ernst Kulli
Displacement Measuring Device
Compensation of thermal and mechanical spindle growth
Ernst Kulli
Thank you for your attention
Ernst Kulli
Senior Engineer
Fischer AG Przisionsspindeln
3360 Herzogenbuchsee
www.fischerprecise.ch
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