The Value of Tool Monitoring on Rotary Transfer Machines

Speeding production processes for sophisticated CNC machine tools, especially for high-volume rotary transfer machines, can be challenging. And the tasks become more complicated when a machine shop runs more than one of these machines on its shop floor.

Implementing a cutting tool monitoring system to detect and/or avoid tool breakage, machine damage, unexpected machine downtime and excess material scrap is advantageous as is detecting tool wear to minimize the number of times production is halted for tool changes.

By using a tool monitoring system such as miTool by Mikron’s machining division, shops can save costs associated with machine maintenance and downtime for tool changes while increasing cutting performance. Best suited for rotary transfer machines, this system can improve production processes and profitability by adapting cutting tool parameters. This results in an increase in quality and the need for fewer tool changes – and therefore less process interruption.

The miTool, which is capable of monitoring 200 channels at once, offers three functionalities, according to Enrico Tumminaro, executive vice president and head of global service, machining division at Mikron Switzerland AG. First, it detects the breakage of the cutting tool. Second, by using artificial intelligence (AI) and a machine learning model, the system can predict the end of a tool’s life. Third, it stops the machine at the optimal time to change the tool (this functionality is still being refined by Mikron, Tumminaro says).  

Detecting Tool Wear for Simultaneous Tool Changes

The company’s goal for miTool is to minimize the number of stops a machine must accommodate for tool changes. Tumminaro points out that although this method might mean a cutting tool is changed out prior to the end of its full life, it is still more beneficial for the machine to have fewer interruptions. This is not only more efficient for the machine but also enables higher speeds and feeds safely. A nonstop (or “less stop”) process also enables unmanned and lights-out shifts.

To accommodate fewer stops, Mikron has created an algorithm for miTool that detects tool wear for optimal intervals for changing several cutting tools at the same time. Detection involves automated learning of load limits within the system, which is sensorless (there is an option to integrate vibration and temperature sensors on the tools or toolholder). When it is time to change tools, the system can be programmed to send a notification to the user to perform the action.

Ease of Use

Mikron designed the system for easy access to monitor data via the miTool dashboard, which uses a simple web browser. For the optimization of the entire production process, statistical data for each tool is collected and accessible, including the number of tool changes and number of broken or life-expired tools.

Users can save tool configuration data and history in the database and preventively stop the machine. However, modifications are possible such as modifying the channels’ configuration (for example, limits, threshold) without stopping the machine.

Part of a Larger System

The miTool is part of a larger interprocess communication system called Mikron miS4.0 that collects, stores and normalizes Mikron machine data, enabling a machine shop to have a complete overview and control of its production and machine tools’ overall equipment effectiveness (OEE). The system notifies

The miTool detects tool wear for optimal intervals for changing several cutting tools at the same time.

operators or maintenance workers of machine status changes and critical machine conditions. Also, production data can be transferred from the machine to a mobile device. It also offers an Industry 4.0 cloud platform to manage the data and improve machining processes and predictive analysis.

Alongside miTool, the miS4.0 system is based on three other popular Mikron applications:

• miEnergy — This energy consumption monitoring system monitors machine current, power, compressed air, and oil and coolant temperature. It detects anomalies, and regulates and controls the machine based on the needs of that particular application.
• miMaintenance — Monitoring maintenance by usage, this system complements preventive maintenance checks. It also offers automated machine expertise as well as support to maintenance planning through predictions.
• miMachine — This feature monitors machine conditions, including new status, production status and more. It provides a digital bill of materials and back-end integration with Mikron ERP.