In-Prozess-Regelung

Dank einer aktiven Prozessregelung ist das Produzieren fehlerfreier Werkstücke „auf Anhieb” möglich.

Diese Stufe der Produktionsprozess-Pyramide (Productive Process Pyramid™) zeichnet sich durch Regelmechanismen aus, die direkt in die spanende Bearbeitung eingebunden sind. Diese aktiven Regelungen reagieren automatisch auf Materialzustände, interne Prozessschwankungen und ungeplante Ereignisse, um Prozessabweichungen zu minimieren.

Behalten Sie die Kontrolle während die Bearbeitung läuft

Die Produktionsprozess-Pyramide (Productive Process Pyramid™) - In-Prozess-Regelung Die Stufe der In-Prozess-Regelung in der Pyramide befasst sich mit Abweichungsquellen – Werkzeugverschleiß und Temperaturschwankungen – und bietet während der spanenden Bearbeitung intelligentes Feedback zum Prozess und zur Entscheidungsfindung.

Hierbei handelt es sich um aktive Regelungen, die während des Zerspanens zum Einsatz kommen.

Laufende Werkstückmessung erlaubt...

die Anpassung der spanenden Bearbeitung an Schwankungen im Bearbeitungsprozess, wie beispielsweise Werkstückverformung, Werkzeugabdrängung und thermische Effekte.
die Aktualisierung von Koordinatensystemen, Parametern, Korrekturen und logischen Programmabläufe, abhängig von den tatsächlichen Materialzuständen

Werkzeugbruchkontrolle erfasst ...

das Vorhandensein eines Werkzeugs
die Position des Werkzeugs - um sicherzustellen, das es nicht herausgezogen wurde
beschädigte und/oder gebrochene Werkzeugschneiden

Aktive Regelung

Dank einer aktiven Prozessregelung ist das Produzieren fehlerfreier Werkstücke „auf Anhieb” möglich, sodass keine Kapazitäten für Nacharbeiten oder Neufertigung vorgehalten werden müssen.

Die automatisierte Messung während des Prozesses bedeutet, dass Ihre Maschinen nicht mehr auf einen Neustart durch den Bediener warten müssen.

Durch Messungen im Bearbeitungszyklus erhält die Werkzeugmaschine die Informationen, die sie braucht, um selbst Entscheidungen zu treffen. Die Zeiträume der vollautomatischen Bearbeitung werden somit länger und die Produktivität steigt.

Renishaws Messtaster zum Prüfen von Werkstücken, TRS2 System zur Werkzeugbrucherkennung und Productivity+™ Software passen die spanende Bearbeitung an die tatsächlichen Material- und Umweltparameter durch automatische Ergebnisrückführung an.

Produktive Prozessmuster

Educational article: (AP301) Productive Process Pattern: Cutter parameter update [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure the actual size of a machined feature and update the relevant tool offset.

Educational article: (AP301) Productive Process Pattern: Cutter parameter update

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure the actual size of a machined feature and update the relevant tool offset.
[485kB]
Educational article: (AP302 addendum) Productive Process Pattern: Three pillar test piece: an example of dynamic re-machining [en]
Explanation of machining processes and strategies used to produce the three pillar test piece, and aid in demonstrating the benefits of in-process control.

Educational article: (AP302 addendum) Productive Process Pattern: Three pillar test piece: an example of dynamic re-machining

Explanation of machining processes and strategies used to produce the three pillar test piece, and aid in demonstrating the benefits of in-process control.
[346kB]
Educational article: (AP302) Productive Process Pattern: Dynamic re-machining [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. The CNC machining process uses semi-finishing cuts or test cuts (slave features) that are representative of the subsequent finishing cut. The probing system on the machine is used to measure the cut feature and adjust the process through tool offsets to improve final part accuracy (using pattern AP301, Cutter parameter update).

Educational article: (AP302) Productive Process Pattern: Dynamic re-machining

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. The CNC machining process uses semi-finishing cuts or test cuts (slave features) that are representative of the subsequent finishing cut. The probing system on the machine is used to measure the cut feature and adjust the process through tool offsets to improve final part accuracy (using pattern AP301, Cutter parameter update).
[810kB]
Educational article: (AP303) Productive Process Pattern: Thermal correction - machine drift [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to locate and measure the position of a critical reference feature in order to detect machine drift, or use an on-machine tool setter to track movement in a machine’s Z-axis caused by thermal effects.

Educational article: (AP303) Productive Process Pattern: Thermal correction - machine drift

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to locate and measure the position of a critical reference feature in order to detect machine drift, or use an on-machine tool setter to track movement in a machine’s Z-axis caused by thermal effects.
[1.0MB]
Educational article: (AP304) Productive Process Pattern: Tool condition monitoring [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. When tool breakage is identified as a significant expected risk, it is useful to monitor the condition of the cutting tools which are being used. Performing a tool breakage check immediately after using a tool can help to infer whether the component has been correctly machined - particularly for components where tool breakage is the primary cause of failure.

Educational article: (AP304) Productive Process Pattern: Tool condition monitoring

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. When tool breakage is identified as a significant expected risk, it is useful to monitor the condition of the cutting tools which are being used. Performing a tool breakage check immediately after using a tool can help to infer whether the component has been correctly machined - particularly for components where tool breakage is the primary cause of failure.
[187kB]
Educational article: (AP305) Productive Process Pattern: In-process datum setting [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure datum features then store feature or part locations in the CNC in order to reset a current work coordinate system (WCS), or define a new WCS automatically. This procedure can be carried out whenever it is required during a machining process.

Educational article: (AP305) Productive Process Pattern: In-process datum setting

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure datum features then store feature or part locations in the CNC in order to reset a current work coordinate system (WCS), or define a new WCS automatically. This procedure can be carried out whenever it is required during a machining process.
[261kB]
Educational article: (AP306) Productive Process Pattern: Thermal correction - workpiece expansion [en]
Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a spindle probe to measure the size of a reference feature in the machine environment and compare it with the known size of that feature at 20 °C. Produce and apply a scaling factor or offsets to subsequent part measurements and proceed with machining operations based on parameters corrected for thermal effects.

Educational article: (AP306) Productive Process Pattern: Thermal correction - workpiece expansion

Productive Process Pattern™ from the in-process control layer of the Productive Process Pyramid™. Use a spindle probe to measure the size of a reference feature in the machine environment and compare it with the known size of that feature at 20 °C. Produce and apply a scaling factor or offsets to subsequent part measurements and proceed with machining operations based on parameters corrected for thermal effects.
[1.0MB]