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    02 Presentazione Fischer

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    adga rwerwe
    The document discusses the use of sensors in spindles for machining applications. It describes how sensors integrated into spindles can monitor conditions like temperature, vibration, and forces. This allows issues to be detected early and machining processes to be optimized. Case studies show how sensor data and analysis can improve high-performance cutting and precision machining. Features like smart vision and smart drive allow process monitoring and analysis in real-time to achieve stable cutting conditions and maximize productivity.

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    02 Presentazione Fischer

    Uploaded by

    adga rwerwe
    88 views11 pages
    The document discusses the use of sensors in spindles for machining applications. It describes how sensors integrated into spindles can monitor conditions like temperature, vibration, and forces. This allows issues to be detected early and machining processes to be optimized. Case studies show how sensor data and analysis can improve high-performance cutting and precision machining. Features like smart vision and smart drive allow process monitoring and analysis in real-time to achieve stable cutting conditions and maximize productivity.

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    The document discusses the use of sensors in spindles for machining applications. It describes how sensors integrated into spindles can monitor conditions like temperature, vibration, and forces. This allows issues to be detected early and machining processes to be optimized. Case studies show how sensor data and analysis can improve high-performance cutting and precision machining. Features like smart vision and smart drive allow process monitoring and analysis in real-time to achieve stable cutting conditions and maximize productivity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    88 views11 pages

    02 Presentazione Fischer

    Uploaded by

    adga rwerwe
    The document discusses the use of sensors in spindles for machining applications. It describes how sensors integrated into spindles can monitor conditions like temperature, vibration, and forces. This allows issues to be detected early and machining processes to be optimized. Case studies show how sensor data and analysis can improve high-performance cutting and precision machining. Features like smart vision and smart drive allow process monitoring and analysis in real-time to achieve stable cutting conditions and maximize productivity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 11

    GIORNATA DI STUDIO SU UTILIZZO DI

    SENSORI PER IL MONITORAGGIO DI


    MANDRINI PER FRESATURA E RETTIFICA
    Usage of sensors in the spindles for
    high 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

    4.

    a.

    SmartVision

    b.

    SmartDrive

    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

    ~ 4000 BC.

    The name

    stands for

    PRECISE, FAST and POWERFUL rotation

    Ernst Kulli

    Quo vadis?

    Precision

    Speed

    Power / Torque

    Precision parts

    Grinding

    High Power

    Surfaces

    Small tools

    High Torque

    Ernst Kulli

    Bearing

    Ball bearing

    Air bearing

    Hydrostatic

    Angular contact ball


    bearings

    Static
    Compressed air is introduced

    Cylinder roller bearings


    and others

    Dynamic
    Air cushion is built up by the
    movement itself

    Static
    Liquid is introduced under
    pressure
    Dynamic
    Pressure in the fluid builds
    up by the pumping action of
    the two part surface

    Ernst Kulli

    Magnet

    Contact free
    Bearing forces is
    generated by controlled
    electromagnets

    Contents
    1.

    Introduction

    2.

    Spindle integrated sensors

    3.

    Case study of high performance cutting

    4.

    a.

    SmartVision

    b.

    SmartDrive

    Case study of precision machining


    a.

    DMD

    b.

    Shaft cooling

    Ernst Kulli

    Sensors
    Force flow of bearings

    Motor temperature
    Shaft angle position

    Bearing temperature

    Flow rate
    Axial position of
    interface
    Leckage
    Structure
    acoustic noise
    Speed

    Number of tool changes


    Vibration level

    Ernst Kulli

    Current

    Voltage

    Sensors
    Visualize the condition of the spindle
    Records the measured datas
    Analysis exceeded warning levels
    Registered alarms
    Allows to create reports
    Smart Vision

    Safe operation of spindle


    Optimization of the machining process

    Ernst Kulli

    Sensors
    14

    Schnitttiefe ap [mm]

    12
    10
    8
    6

    Itotal = 139 mm

    4
    2
    0
    23000

    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 rt m e t a ll
    V o lln u t, f z = 0 ,1 8 m m

    s ta b ile r S c h n itt
    R a tte r n
    E x p e r im e n te lle S ta b ilit ts k a rt e

    24000

    25000

    26000

    27000

    28000

    29000

    Ia = 48 mm
    30000

    D r e h z a h l [1 /m in ]

    14

    s ta b ile r S c h n itt
    R a tte rn
    E x p e rim e n te lle S ta b ilit ts k a rte

    Schnitttiefe, ap [mm]

    12

    F r s e r N r. 7 9 6 8 5 7 1 , D 1 6
    l g e s = 1 6 6 ,5 m m , l a = 7 5 ,5 m m
    2 S c h n e id e n , V o llh a rtm e ta ll
    V o lln u t, f z = 0 ,1 8 m m

    10
    8
    6
    4

    Itotal = 166.5 mm

    2
    0
    20000

    21000

    22000

    23000

    24000
    25000
    26000
    D r e h z a h l [ 1 /m in ]

    27000

    Ernst Kulli

    28000

    29000

    30000

    Ia = 75.5 mm

    Sensors
    Machining forces

    Force [a.u.]

    5 revolutions

    Time [a.u.]
    Ernst Kulli

    SmartVision Report
    Customer send his recorded SmartVision Data back
    for 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

    4.

    a.

    SmartVision

    b.

    SmartDrive

    Case study of precision machining


    a.

    DMD

    b.

    Shaft cooling

    Ernst Kulli

    High Power Milling


    Example: Aeronautical structure parts
    With spindle power of over 150 kW  material
    removal rate of > 15 l/min are achievable.

    Fischer converter

    MFW-2715/20

    MFW-2320/30

    for high power

    150 kW, 96 Nm S1

    100 kW, 48 Nm S1

    Ernst Kulli

    High Torque Milling


    Example: Structure parts for energy
    generation
    High torque for roughing and high speed for
    finishing are necessary to mill difficult
    machinable materials with long tools

    MFW-2801/16

    MFW-2702/08

    198 Nm, 28 kW S1

    445 Nm, 93 kW S1

    Ernst Kulli

    SmartDrive
    Strong
    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 Analysis


    View 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

    4.

    a.

    SmartVision

    b.

    SmartDrive

    Case study of precison milling


    a.

    DMD

    b.

    Shaft cooling

    Ernst Kulli

    o
    nan

    Thermal constant process condition


    Benefits
    1. Shortening the time until
    saturation of temperature
    Time reduction -80%

    Spindle temperature

    Shaft cooling

    Without shaft cooling

    Shaft cooling
    Time

    Ernst Kulli

    Thermal constant process condition


    Benefits
    2. Reduction of shaft elongation

    Shaft cooling

    Without shaft cooling

    Dilatation -70%

    Shaft cooling
    Zeit

    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
    [email protected]
    www.fischerprecise.ch

    Ernst Kulli

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