Process monitoring and control for machining

Know the condition of your tools – and replace them in time. There is a significant correlation between the wear of cutting tools/abrasives and forces and vibrations. Moreover, the achieved product quality and selected cutting data (how fast the cutting process can be performed) relates to the wear of the cutting tool/abrasive as well.

Optimize your process through knowledge building. Manufacturing processes are often designed according to heuristic rules that make the process safe but often do not achieve optimal performance. Piezo-based process monitoring continuously generates high-resolution data that allows a long-term assessment of the system load and can be used to identify optimization potential. By gradually adjusting the parameters, processes can be safely brought to their performance limits. Moreover, by building control loops, manufacturing equipment can react and adapt – not only to the wear of the machine and cutting tools, but also to unexpected abnormalities with respect to the machine and the process. 

Process optimization through knowledge building - Manufacturing processes are often designed according to heuristic rules that are process safe but often do not achieve optimal performance. Piezo-based process monitoring continuously generates high-resolution data that allows a long-term assessment of the system load and can be used to identify optimization potential. By gradually adjusting the parameters, processes can be safely brought to their performance limits in this way. Moreover, by building control loops, manufacturing equipments can react and adapt themselves upon not only wear of machine and cutting tools but also on machine and process unexpected abnormalities.

Decrease the human/machine ratio in new production lines. Sensor solutions for monitoring machines and processes can capture even small and highly dynamic events (expected and unexpected). Since several machines can be monitored and controlled from a single place thanks to the availability of digital “live data”, the number of operators and other supporting functions can be decreased. This will in turn lower the operating cost.

Moreover, once machine and process reliability is improved thanks to monitoring and control of the manufacturing process, the scrap ratio and/or poor quality and related cost will also decrease.

With the help of monitoring and control technology, the digital twin of the entire manufacturing chain can be built. This digital and well-structured data environment improves constantly and enables users to create suitable documentation and other educational tools to increase the skills of workers and managers on various levels.

Thanks to the connected ERP systems of suppliers, manufacturers and customers, the demand on delivery precision is increasing continuously. By monitoring and controlling the manufacturing status, the delivery to the customer can be improved. Moreover, the available data from different manufacturing sites will enable meaningful comparisons and status reporting, as well as improved forecasting and manufacturing/company planning. Thus, decision-making can be improved – not only in factories, but also in management and with respect to the supply chain

Kistler offers measurement solutions for recording and monitoring highly dynamic machining processes based on forces (force and strain), acoustic emissions and vibrations. The company’s robust measurement technology is directly connected to the machine control system and is suitable for applications in harsh environments.

Moreover, Kistler also offers smart maintenance services and trainings in machining applications, CNC machine evaluation and Machining Excellence.