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Mechatronics in Manufacturing Systems

Mechatronic Machine tools
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Mechatronics in Manufacturing Systems

Evolution of Machine tools Single operation (Lathe, milling etc.) NC CNC Merge Multi-operation (Turret, multi-spindle drilling etc.) NC CNC

Machining center
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NC and CNC machine

In case of NC machine the entire data input and data handling sequence including control functions are determined only by fixed circuit interconnections of decisions elements and storage devices. Hence it is required change in circuitry for any additional features Also the machine control data read in time to time from tape.
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NC and CNC machine

A CNC machine incorporates a micro processor based control system that accepts a set of program instructions and sends output control information to the machine tool based on the feed back information received from machine interface elements.

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Mechatronics in Manufacturing Systems ..

Machining Center Essentially a mechatronics machine

Higher productivity Higher accuracy

Requirements of MC
Perform multiple operations Finish all work in one setup
SSM single setup machining SSO single setup operation

Flexibility to handle a variety of components/tools

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Mechatronics in Manufacturing Systems ..

Machining Center

Applied to
First: Prismatic components
with Operations milling, drilling, boring, tapping etc.

Second: Cylindrical components

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Mechatronics in Manufacturing Systems ..

Machining Center

Features of MC
Higher spindle speeds >20 rpm Rapid traversal rates >1 m/s
Faster tool positioning Faster feed

Higher material removal rates Faster tool change ( ~ 0.6 s)

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Mechatronics in Manufacturing Systems ..

Machining Center Features .. Reduced friction

Less heat Better dimensional accuracy Ball bearings Ball screws/slides

Thermal control accuracy Longer tool life Tool magazine no. of tools
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Mechatronics in Manufacturing Systems ..

Machining Center Features .. Digital servo control spindle/feed

Improved accuracy/control

Vibration control - accuracy Tool/work monitoring Minimum operator intervention

Increased safety

Mechatronics in Manufacturing Systems ..

Machining Center Types of machining centers

VMC - Vertical Machining Center
Vertical spindle + Three axes (DOF) - Flat surface jobs

HMC - Horizontal Machining Center

4 sides of a cuboid (4-DOF) + index/rotating table + Tool magazine as many as 32 tools
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Mechatronics in Manufacturing Systems ..

Machining Center Types of machining centers ..

UMC - Universal Machining Center
Both VMC HMC function + spindle change V to H + five (5) faces of cuboid

TMC - Turret Machining Center

Spindle replaced by tool turret + Auto selection of tool - limited tools/operations
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Mechatronics in Manufacturing Systems ..

Machining Center Add-ons for machining centers ..

ATC Automatic Tool Changer
Transfer tool from tool magazine to tool holder and vice versa

APC Automatic Pallet Changer

Loading/unloading a pallet with job clamped Job is clamped on pallet while machining on previous job is going on + ZERO set-up time
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Mechatronics in Manufacturing Systems ..

Machining Center
FUTURE Increased speeds/feeds/MRR
High speed controllers Vibration issues

Robust adaptive control

Improved part accuracy Improved tool life

Measurement/Inspection
Corrective action before the damage Minimize rejection
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Mechatronics in Manufacturing Systems ..

Machining Center
VERTICAL vertical machining centers from Chiron America (Charlotte, NC)

MC

speed: the 5-hp spindle cranks up to 8,500 rpm in 0.4 seconds optional 15,000 rpm and 27,000 rpm spindles (reach top end rotations in 0.6 and 2 s). The standard toolchanger handles 32 tools, can swap in 0.5 s. integral workpiece changer. The axis travels are 11.7 9.8 9.8 in., X, Y, Z.

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Mechatronics in Manufacturing Systems ..

Machining Center
Ex-Cell-O Machine Tool Co. (Sterling Heights, MI) A spindle for aluminum machining rotates at 24,000 rpm Rapid traverse: 120 m/min, with acceleration of up to 1.4 g. Axes travels are 630 mm X and Y and 710 mm Z. rotary table. Chip-to-chip tool changes from the 40position tool mechanism: 4.5 s.

The machining center features pallets measuring 500 500 mm can handle workpieces including transmission, clutch, and converter cases; engine blocks, and cylinder heads. It has a compact footprint of 10 m2.
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Mechatronics in Manufacturing Systems ..

Machining Center
INDIAN Scene
TAL Manufacturing Solutions (a TATA Enterprise, Pune) VERTIMACH Machining Center

Rigid structure Rapid traverse: 30 m/min Spindle speed: 8000/10000 rpm Die and mould milling operations Small and medium batch production
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Mechatronics in Manufacturing Systems ..

Tool Monitoring System

Why?
Get more parts per tool Know when to replace/sharpen Reduced tool inventory Reduction in scrap lower Tool costs reduce machine downtime Lower grinding costs Reduce labour cost
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Mechatronics in Manufacturing Systems ..

Tool Monitoring System Monitoring of tool for

Cutting edge sharpness Hardness of cutting edge Tool geometry Built-up edge damage of tool breakage/wear

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Mechatronics in Manufacturing Systems ..

Tool Monitoring System

Types :
Direct Indirect In-process Preventive Before/after

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Mechatronics in Manufacturing Systems ..

Tool Monitoring System

Corrective action before the damage How? By tool working hours (expected tool life ??) By cutting force measurement By Inspection (too subjective ??) By geometric measurement (vision system) By spindle power consumption By feed drive power consumption Temperature measurement Geometric measurement of product
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Mechatronics in Manufacturing Systems ..

Tool Monitoring System

Solution is only by MECHATRONICS

Functions of Computer (Microprocessor) to keep record of use of each tool in tool magazine of ATC (knowledge base) For force measurement (embedded into tool/tool post) For temperature measurement (embedded into tool) To track power consumption of drives (record)
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Mechatronics in Manufacturing Systems ..

Tool Monitoring System Solution is only by MECHATRONICS

Functions of Electronics

To amplify/condition To warn - alarm To display To transform To take action (actuate)

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Mechatronics in Manufacturing Systems ..

Tool Monitoring System

Laser Tool Monitoring System helps eliminate scrap. April 1, 2003 Laser Control in-process tool management system monitors tools in real-time from within machining environment and certifies that correct tool is intact within specified toolholder. It also verifies length, diameter, roundness, and runout with repeatability of better than 1 micron. Product allows thermal drift of machine axis and tool, to be determined and provides compensation automatically .
Source: http://news.thomasnet.com/fullstory/20852
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