Real-Time Tool Wear Detection
TMAC measures tool wear and detects breakage in real-time by monitoring true spindle motor power. TMAC learns the optimum power for each tool and cutting section, and compares it to the user defined limits to calculate wear as the tool is cutting. It operates on the principle that the power required to cut a part increases as the tool’s cutting edges deteriorate.
- Monitors and reacts to tool wear in real-time
- Uses multi-range sensors with auto-scaling display sensitivity
- Prevents tool breakage and lowers scrap rate
- Reduces the cost of consumable tooling
- Provides valuable information about the cutting process
- Stops the machine instantly in the event of tool breakage
Reduce Cycle Time with Adaptive Control
Adaptive Control regulates feedrates to maintain a constant spindle motor power for optimum cutting and reduced cycle time.
- Automatically adjusts the feedrate for each tool to maintain a constant power in the cut
- Eliminates the need for manual adjustment
- Allows the tool to always cut at its optimum power
- Adjusts for varying cutting conditions
- Typical cycle time savings of 20% – 60%
- Reduces cost of consumable tooling by increasing tool life
- The “advanced” adaptive control option is even more robust for low RPM cutting
Remote System Access
The new streamlined browser-based HMI allows users to access TMAC anytime, anywhere, and from any network connected device (including smart phones).
- Remotely view live cutting data from any TMAC system on your network
- View all TMAC data, change job or system parameters, or access the data viewer to analyze historical cutting data from any location
- Multiple users can be logged in simultaneously (with assigned permissions)
Multi Channel Monitoring
Multiple sensor channels can be monitored simultaneously
For instance, you can monitor power, vibration and coolant for a specific tool and section at the same time, and have unique limits for each sensor and channel.
- Create multiple custom views to look at monitoring data in different ways.
- View up to 4 monitoring channels in a single view
- Toggle between custom views with the touch of a button
- Change background color to easily identify TMAC systems
SENSORS
TMAC has multiple integrated sensor options for total machine condition monitoring.
- TMAC uses high-speed, multi-range power transducers to measure the power load on the tool to determine wear
- In addition to power, vibration and strain sensors can also be used to measure tool wear
- Other peripheral sensors can be installed and monitored by TMAC including spindle speed, coolant flow, and coolant pressure
- GE P11TF12 Compliant
High Speed Data Processing
The CNC control does not have enough processing power for value-added systems like tool monitoring. For this reason, the TMAC system consists of its own dedicated high-speed processor that handles all communication between TMAC, the sensors, and the CNC control.
- TMAC can monitor multiple sensors simultaneously to handle different types of machining challenges and react instantaneously to changing conditions
- Stores all job information and associated learned and monitored data for easy access and repeatability of cutting programs
BEARING ANALYSIS
TMAC monitors spindle bearing health. A CEI vibration sensor is attached to the spindle, hardwired to TMAC, and the bearing analysis is initiated in the CNC part program.
- Results displayed within 5 seconds
- Reports are saved for analysis and trending
- Trend data can be used to establish maintenance requirements
The vibration signal is analyzed for acceleration to detect the health of the bearings, and velocity to detect misalignment, imbalance, and looseness.
Data Viewer and Event Log
View the details of any cut, with pan and zoom options for a closer look!
- All monitored data and events are stored and can be exported in various formats for analysis
- Data files can be opened simultaneously to view graphical differences
- Cutting data files can be overlaid to compare cuts
- CNC position data allows the user to inspect the CNC axis positions, program line number, and spindle RPM to interrogate alarms and anomalies at any point in the cut
Advanced Features and Benefits
- Universal interface easily adapts to CNC controls
- Automatic real-time data graphing
- Increased machine tool utilization with less downtime
- Programmable to call a redundant tool when a wear limit is reached (control dependent)
- Easily monitors tapping cycles
- Eliminates air cutting using the approach feed rate feature
- Seamless communication with third party OEE software via the industry standard MTConnect protocol