Optimizing Process and Tools for Grinding. Modular Process Monitor System PROMOS. operator-supporting uncomplicated retrofittable simply good

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Modular Process Monitor System

PROMOS

PDA.241.086.GB

operator-supporting

uncomplicated

retr

ofittable

simpl

y

good

compatible with automated balancing

equipment from MPM

ð

GAP control

ð

CRASH control

ð

DRESS control

ð

TOUCH dressing

ð

SIZE touching

ð

ADAPTIVE control

ð

ROUND OUT control

ð

CHATTER control

ð

Visualized sensor or process signals (process

analysis) to optimize your operation

ð

Shorter piece times, less scrap, better quality

ð

Operation and Visualization can be integrated in

open NC

Sensors for grinding machines,

Optimizing Process and

Tools for Grinding

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PROMOS system architecture (example)

PROMOS - the key to unlock your rationalization potential

In automated production, interest is increasingly focused on process reliability. Low-cost, competitive production is possible only with controlled and optimized machining processes. In the grinding machining field, this results in a demand for effective on-line monitoring of tools and processes, together with a process analysis system which can be adapted to a wide range of machine tools and grinding

processes tasks - like PROMETEC´s Modu-lar Process Monitor System: PROMOS. Despite its great flexibility and wide range of options for all modules - sensors, machine interfaces, monitor units and control modules - PROMOS is uncomplicated, sim-ple to install and user-friendly.

PROMOS always gives you the optimum low-cost solution - from simple spark-in

Optimizing Process and Tools for Grinding - PROMOS will meet your demands

Whether you make use of the full range of modular options for monitoring, control, visualization, machine interface or sensors, or use only selected elements, the systematic modular concept embodied in PROMOS opens the way to monitoring applications which we can optimize to fit your particular operation.

You get maximum functionality at low cost with no complications.

System architecture

Sensor signals are analyzed by monitor modules. Different models with different options in terms of the range of monitoring functions and the number of monitored cycles (operation steps) are available. You can also choose modules in single-channel or two-single-channel versions. For example: a two-channel monitor module is the lowest-cost solution for a grinding machine with two grinding spindles, where a single-channel monitor module would be the standard choice for a grinding machine with only one spindle. With PROMOS you

can operate up to 15 monitor modules from the same operator panel module. Sensor-specific sensor modules or sensor terminals are available to feed sensor signals to the monitor module.

The monitor module transfers alarms (breakage, wear etc.) to the machine SPC via a machine interface module. The interface module is supplied in a number of variants, including the BAPSI® standard or the MINI version, respectivlely, which is sufficient for grinding machines most of the time.

PROMOS Modules

Operator Panel Modules

You have the choice:

The Modular Process Monitor System can be operated either from a PROMETEC operator panel module, from a PC or laptop or directly from an open NC control system, using appropriate PROMETEC software. With the operating software for the PROMOS modular Process Monitor System you have your process under control – the software comes complete with the OPM 20 operator panel module or as a special package for open NC controls and PC´s. detection (GAP control) to an all-round system which visualizes your grinding operation for process analysis and optimization and gives you 100 % process control.

Reliability is the crucial factor! That´s why all PROMETEC monitoring units for grinding operations - including PROMOS - come complete with CRASH control.

Co-ordinate grinding machine application

Cylindrical surface grinding machine application

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Apart from controlling monitoring operations, the OPM 20 or the standardised software provides extensive options for visualising the signal and hence for diagnosing and optimizing machining operations.

The very low-cost OPM 12 control module can also be used to set up the monitoring system without difficulty, even for complex machining tasks. A bar display shows the limits and the signal. The user-friendly menu structure is identical with the OPM 20 software.

Both control modules are fitted with a serial interface (RS 232) for the transfer of

Monitor Modules

The monitor modules in the MSL 3000/5000 series use fixed limits.

So that optimum prices and functions can be offered for specific machining tasks, the modules are designed for between 2 and 250 monitorable cycles and 2 to 6 different static limits. The static limits are used for monitoring; appropriate limits for each monitoring cycle are chosen from a group of 6 to 8 thresholds. They are related to the sensor signal for normal undisturbed machining.

The various monitor modules perform their monitoring tasks separately, optimized for each work station. The sensor signal for each cycle is calibrated automatically in a teach-in (or manual) phase during machining of the first workpiece and the limit positions are specified.

Monitor modules in the MSL 5000 series have extended monitoring functions like storage of monitoring data under the appropriate program number.

Standard assembly of the monitor and sensor modules is in an EMV-proof protective enclosure supplied with the package and designed for fitting in a switch cabinet.

monitoring data between NC, PC, NC-feeder, cell computer etc. and the monitor modules. This means that the monitoring system can be re-set automatically after a tool change.

Given a laptop, a modem and a telephone (cellular phone) you can use the RS 232 interface for remote diagnostics and remote servicing of the Modular Process Monitor System by the machine manufacturer or PROMETEC.

With a laptop and the RS 232 interface, you can also use the OPM 12 operator panel

module to visualize the sensor signal and carry out user-friendly commissioning and servicing functions.

Operator panel modules are fitted in the front panels of control stations etc. Alternatively, the OPM 12 operator panel module and the plug-in module can be supplied for 19“ rack fitting with 3 HE. There is also the option of fitting both operator panel module types in a protective enclosure for wall and free-standing fitting. In this case, the on-board RS 232 and printer interface have standard external connections.

Type OPM 12 OPM 20

Display LCD 4 x 20 Charact. full-VGA color or monochrome RS 232 for PC, modem etc. l l Printer interface LPT m l Plug-in module for

ext. connector RS232 or printer interface

optional optional

Protective enclosure optional optional

Machine interface module Type

MINI MIDI BAPSI

1-channel Cycles Alarm outputs 8 3 -250 7 2-channel Cycles Alarm outputs 2 1 30 3 250 7

_{+ one additional common output for}

both monitoring channels

_{For 2-channel operation and two}

BAPSI interface modules

Machine Interface Modules

All machine interface modules are supplied in appropriate EMV-proof protective enclosure for fitting in a switch cabinet. The main functions of the 3 interfaces are shown in the accompanying table. Please refer to the interface plans or descriptions for furt-her details.

All signal inputs and outputs on the MIDI and MINI machine interface modules comply with the BAPSI® standard.

Limit type Example

Overload Underload Contact Missing (switches at end of cycle) Rising through Falling through (MSL50xx only) Work over Work under (switches at end of cycle) M onitor module type Channels Cycles per channel Limits M SL 3011 1 2 2 of 6 M SL 3012 2 2 2 of 6 M SL 3031 1 8 3 of 6 M SL 3032 2 8 3 of 6 M SL 3041 1 16 4 of 6 M SL 5051 1 30 6 of 8 M SL 5052 2 30 6 of 8 M SL 5071 1 120 6 of 8 M SL 5072 2 120 6 of 8 M SL 5081 1 250 6 of 8

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PROMOS combined with MPM balancing units

Complete sytems from a single supplier

MICRO PRÄZISION MARX GmbH in Erlan-gen and PROMETEC GmbH, Aachen joined forces in June 1996 to develop and market ancillary systems for grinding machines. MPM makes manual, semi-automated and fully-automated balancing units for grinding wheels. The low-priced high-precision units use a wireless remote control for the balancing motors – the CONLESS system.

MPM and PROMETEC have made their systems compatible. PROMOS system components are also easy to combine with MPM automatic balancing equipment. If you prefer, you can order the complete package from a single supplier—PROMETEC or MPM.

Automatic balancing unit from MPM combined with PROMETEC grinding and dressing monitoring

Change of balancing mass value and position

Sensors

PROMETEC offers a comprehensive range of effective, reliable sensors, proven in thousands of industrial applications. Grinding operations are monitored by standard acoustic emission sensors fitted on the headstock or dresser unit. The AEL 200 structure-borne sound sensor can also be mounted directly on the end of the spindle, with wireless signal transmission. This technique offers particularly high resolution, with an excellent signal-to-noise ratio. Other PROMETEC sensors may be used for special applications.

Inductive displacement sensor for force and elongation

Hall current sensor for effective power Fluid sound sensor for structure

borne sound and accoustic emission via coolant flow from workpiece

Wide band sensor for structure borne sound and accoustic emission

Wireless sensor for structure borne sound and accoustic emission

Fitting of wireless sensor at the end

of spindle _{and vibration sensor}Accoustic emission

Sensor and transmitter

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Monitor modules in compact protection box with space for 2

sensor modules

Machine interface modules BAPSI or MIDI

Machine interface module MINI

Protection box for panel mounting without top-hat rail holes for 2 x M4 screws 60 mm center-to-center for top-hat rail fitting note 10.5 mm depth between monitor module and top-hat rail for snap-on elements! Dimensions without snap-on elements

(Width x height x depth) 67 x 106 x 169

Power supply 24 V DC ± 20%, 600 mA 24 V DC ± 20%, 600 mA Power supply from monitor module

Operator panel module OPM 12 Operator panel module OPM 20

Views (not to scale)

Dimensions for front mounting - in a 19" system

- with protective rails

(Width x height x depth) 106,5 x 128 x 38 106,5 x 130 x 38

(Width x height x depth) /

271 x 172,5 x 72 Mounting cut-out for front

mounting

(Width x height) 101 x 112

(Width x height) 256 ± 0,3 x 156 ± 0,3 Drill holes for front mounting (Width x height)

91,4 ± 0,1 x 122 ± 0,1 (4 x Ø3,3 or M3) (Width x height) 230 ± 0,1 x 163 ± 0,1 (6 x Ø4,3 or M4) Dimensions of enclosure

- without external securing latches - with external securing latches

(Width x height x depth) 140 x 180 x 70 140 x 200 x 72

/ Drill holes for enclosure

- without external securing latches - with external securing latches

(Width x height) 103 x 165 125 x 192 (Width x height) 280 ± 0,1 x 180 ± 0,1 / Power supply 24 V DC ± 20%, 300 mA 24 V DC ± 20%, 850 mA

Dimensions and connection data

Connection to monitor module 2 x 0,25 mm2_{, twisted pair, screened, max. length 100 m, max. 50 m between 2 modules}

Connection monitor/ interface modules

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Examples how to optimize your grinding process with PROMOS:

GAP control

Reduced air grinding time via GAP control (contact detection)

• Reduced piece times • Reduced costs

• Enhanced process reliability due to integrated CRASH control function • Automatic introduction of the grinding

wheel for tooth flank and thread grinding etc.

• Visual monitoring of the dressing operation

DRESS control:

• Reduced dressing strokes • Minimized grinding wheel costs • Improved quality due to monitoring of

dressing results

• Visual Control of dressing process • Post-process workpiece fault detection

during dressing (see figure):

Grooves in grinding wheel ð welts on the parts ð check parts up to last dressing operation

TOUCH dressing & SIZE touching

Low infeed with TOUCH dressing

• Determining exact grinding wheel radius via machine control by means of highprecision contact detection -SIZE touching

• Low-infeed dressing confined to projecting grits - TOUCH dressing • No surface sharpening needed, since

grinding capacity of the wheel is unaffected

• Minimized consumption of abrasive through sensor-assisted dressing infeed

• Long grinding wheel life

ADAPTIVE control:

Adaptive control for co-ordinate grinding

• Time saving through controlled feed movement

• Improved quality through determination of effective grinding wheel diameter, SIZE touching

ADAPTIVE control:

Adaptive control for grinding large eccentrical or noncircular parts

• Fast detection of maximum workpiece diameter related to workpiece fixture via contact detection

• Time saving via circumferential speed control referred to grinding / air cut via variation of workpiece speed

ROUND OUT control

with grinding and dressing

Removal of concentricity mistakes

• Monitoring the required concentricity in grinding and dressing operations • No unnecessary stock removal in

cylindrical grinding. The process can be interrupted as soon as the required part concentricity is attained.

• Monitoring the workpiece for waviness • Achieving high concentricity in dressing

operations, with special attention to dynamic signal components in the monitor

• Improved part quality with concentric grinding wheels

CHATTER control

• Enhanced quality through detection of chatter phenomena from the signal dynamics

Sensor-controlled deburring

Grinding wheel contour tracing

• Exact workpiece position determination • Shorter air machining times

• Grinding wheel diameter compensation • Reliable contour tracing

PROMETEC GmbH Jülicher Str. 338 D-52070 Aachen Tel.: 0241/16609-0 Fax.: 0241/16609-50 Your representative:

Quality assurance systems, sensors, monitoring systems for machines,

processes and tools

Daugther companies and representatives in Europe, America und Asia