Machsync

MachSensing can be applied to all machining measurements, including milling, tapping, grinding, drilling, and even friction stir welding for tool life monitoring. The measured data shows the physical phenomena of the cutting tool or grinding wheel can be monitored in real-time, and the process can be recorded. Direct connection to the controller achieves high-level intelligent manufacturing, and the following applications are extended:

• Improve production stability: Quality is one of the most challenging issues to control and maintain in mass production. Real-time monitoring of the quality wear and tool breakage prediction during processing can bring stability and reduce the probability of scrap and secondary machine crashes.
• Find the suitable machining tool: Sometimes, experience is used to determine which tools to use for machining, but it is likely to underestimate or overestimate the performance of the tool itself. Calculating tool wear changes and KPIs through data can effectively help the tool magazine investment calculation of the machine tools and even evaluate the benefits of customized tools.
• Maximize machine tool limits: When the process is optimized to shorten processing time and maintain tool life and when a reasonable cutting fluid is used as a lubricant and heat dissipation medium.
• Big data analysis: Incorporating machining behavior data collected into cross-comparison and trend analysis can reveal hidden costs and idle working hours, and the data can be used to maximize the production process.
• Rapid research and development: It can analyze and quickly clarify the development direction for various factors that affect tool life, such as tools, processes, machine tool performance, cutting fluids, coatings, and machining material properties.
• Improve customer satisfaction: It can not only improve product quality in development but also assist customers in adjusting the use of tools and machining paths so that digitization can continue instead of simply attributing the cause to the machine or other factors.