Caron Engineering Inc  

116 Willie Hill Rd
Wells,  ME  04090

United States
207-646-6071
https://www.caroneng.com
  • Booth: 5432

CARON ENGINEERING INC. is an employee-owned company that has been developing advanced sensor and monitoring technology for the manufacturing industry since 1986. They have developed a suite of smart manufacturing solutions to reduce cycle times, promote unattended operations, drive down tooling costs, and minimize expensive damage to machines and work-holding.  

Products include:

TMAC 3.0 Real-time tool wear and breakage detection system with adaptive control feed rate optimization capability. TMAC maximizes tool life, reduces cycle time, allows unattended operation, and stops extreme conditions in their tracks. The new browser-based user-interface allows remote access to live monitoring and system control from any network connected device. 

AutoCompProcesses electronic gauge data and calculates and compensates tool offsets in the CNC control automatically; providing fast, error-free tool offset control.

DTect-ITDetects irregularities anywhere on your CNC machine using high precison sensors and a multitude of analysis options.  Prominant applications include vibration analysis, bar feeder vibration detection, spindle bearing analysis, tool wear monitoring, signature analysis, and surface roughness detection.

ToolConnectReduces setup time and eliminates human error by automating the tool load process; ToolConnect is a customizable tool data management system that uses RFID tags embedded in tool holders and 2D barcodes to transfer tool presetter data directly to the machine control. 

CEI Smart LightIntuitive status light system with over 1000 available modes and programmable audible alarm; to indicate any machine status or condition.

www.caroneng.com

Watch the Company Video!


 Press Releases

  • Caron Engineering has announced a major update release of their Adaptive Tool Monitoring system, TMAC version 3.0.  

    TMAC is a real-time tool wear detection system that uses high-precision, multi-range sensors to determine if a tool is worn or broken. Caron Engineering sensors are 10 times more sensitive than other sensors on the market, allowing TMAC to cover a wider range of tools. TMAC has a separate high-speed processor that collects data at 200 times per second, and directly interfaces with any CNC control, to react instantly to wear and extreme conditions.

    TMAC 3.0 has been completely redesigned with an intuitive streamlined user-interface that offers numerous configurations for viewing tool monitoring and sensor data.  The TMAC system processor now houses its own web server, making the HMI (human-machine interface) browser-based, which enables real-time monitoring from any network connected device. Users (with assigned permissions) have live access to all TMAC systems on a shop floor from a single browser.  Securities and permissions can be customized for each user to assign system access based on their user role and job function.

    TMAC has an adaptive control mode that optimizes cutting with changing conditions due to wear, variations in material hardness, consistency, and depth of cut. Using a power sensor to monitor motor power, TMAC overrides the machine tool feedrate to maintain a constant spindle motor power during cutting. This enables TMAC to increase the feedrate with low power cuts and decrease with high power cuts, and as tools wear. No operator intervention is necessary when TMAC is monitoring and controlling, making it ideal for unattended operations. Users will see an immediate increase in productivity, extended tool life, and overall reduction in cycle time (up to 60%). Cycle time savings are most significant with hard and difficult to machine materials.

    In addition to power, TMAC monitors sensors for vibration, strain, coolant pressure and flow, and spindle speed. The newly enhanced HMI has expanded the monitoring capabilities with TMAC. Users can customize views to show up to 4 sensor channels simultaneously in a single view.  For example, the user can set up a single (split-screen) view to monitor power, vibration, spindle speed, and coolant for a specific tool and section at the same time; and have unique limits for each sensor and channel.  A user can create unlimited views to show data in a variety of ways, and easily toggle between views during monitoring.  Using a vibration sensor TMAC also monitors spindle bearing health, with the analysis initiated by calls in the CNC program.

    The TMAC data viewer and event log stores all cutting data and events. Any number of data files can be opened simultaneously to easily view graphical differences and allows overlaying cutting data to compare and analyze cuts.

    “TMAC’s universal interfacing compatibility with any CNC control allows us to not only monitor processes and detect anomalies, but make real-time automatic (corrective) adjustments, without the need for human intervention.  This is true of all Caron products,” said Rob Caron, President of Caron Engineering.

    ****

    For more information, contact:

    Caron Engineering, Inc.

    116 Willie Hill Rd.

    Wells, ME  04090

    207-646-6071

    marketing@caroneng.com

    www.caroneng.com

    TMAC website page: https://www.caroneng.com/products/tmac

    TMAC New Features Explained Video: https://youtu.be/RlnBN8TmcRY

    TMAC Product Release Video: https://youtu.be/nSMzrwGEfWs     

  • Caron Engineering’s ToolConnect is a process control system that automatically transfers tool measurement data that is generated by a tool presetter and sends it directly to the CNC control.  This system was designed for tools with RFID tags embedded in tool holders as the primary data carriers. Now, ToolConnect can also transfer tool measurement data via 2D (presetter) printed barcode tags.

    The ToolConnect barcode application uses a barcode scanner at the machine tool to scan the presetter generated barcode. ToolConnect reads and processes the barcode data, displays all tool and process information and then automatically updates the offsets to the correct fields in the control. No operator data entry is required.

    In addition to displaying and verifying the tool information on the screen, ToolConnect guides the user through each step of the process to further automate and prevent error. The user screens can prompt the operator through tasks, such as (1) scan the barcode, (2) confirm the tool information, (3) open the carousel door, (4) insert the tool into the (automatically indexed) position, 5) close the door, and other possible scenarios a user requires. The offsets will not be sent to the CNC control until ToolConnect has verified the correct tool is loaded into the machine and each customer-defined step in the process is successfully executed.

    With ToolConnect, the system is designed to fit the users’ tool load specifications. This includes customized user screens, process flow, initial setup and system checks, and general access to the system. The system is flexible and can accommodate changes at any time. Additionally, ToolConnect has an audit log that records every step, action and data exchange, marked with date and time stamp. This data is available locally or via MTConnect; used for quality control and process verification.

    A presetter is an extremely valuable and accurate device for measuring your tools offline. Using ToolConnect in combination takes this measurement data directly to the offset table in the CNC. This eliminates error associated with manual data entry and automates the tool load process. The universal machine tool compatibility of ToolConnect provides a common interface across all machines on your shop floor, increasing operator efficiency.

    Adding the barcode scanning capability to ToolConnect provides a more affordable option for customers who do not need the extensive capabilities of the more robust and continuously reusable RFID system.

    For more information, contact:

    Caron Engineering, Inc.

    116 Willie Hill Rd.

    Wells, ME  04090

    207-646-6071

    marketing@caroneng.com

    www.caroneng.com

    ToolConnect Website Page: https://www.caroneng.com/products/toolconnect

    ToolConnect Demo Video:  https://youtu.be/cwy3SJfvy0c

  • Caron Engineering Product Preview: EASTEC BOOTH #5432

    Smart Technology for Unattended Operations

    At EASTEC 2021, Caron Engineering will feature their smart technology suite of solutions that optimize the entire manufacturing process; before, during and after cutting.

    All products will be demonstrated on a Tsugami swiss-style machine. Caron Engineering’s tool data management system, ToolConnect, will automate the process of loading tools into the machine. ToolConnect reads and processes presetter written RFID tags, and 2D printed barcode tags to automatically update tool information directly to the CNC control, and further prevents a wrong tool from being loaded into the machine. During cutting, they will feature their adaptive tool monitoring system, TMAC, capable of monitoring even the slightest cutting operations in real-time and will stop the machine instantly in the event breakage is detected. Using electronic gauging to measure the part, post-machining, Caron Engineering’s AutoComp software will automatically process the measurement data to calculate and compensate offsets in the control. All these solutions successfully eliminate operator error, reduce cycle and setup times, and allow unattended operations.

    At EASTEC, Caron Engineering will also focus a lot of attention on their newest product, DTect-IT. DTect-IT uses a variety of sensors to monitor different areas of the machine, as measured against user-specified parameters, to keep all processes in check. DTect-IT has countless applications including vibration and bearing analysis, tool wear detection, bar feeder vibration detection, and the newly added signature analysis and surface roughness monitoring.

    Caron Engineering’s solutions are unique in the fact they can interface with nearly any CNC machine tool on the market and can be customized for almost any application. Their high precision sensors are infinitely scalable to accommodate all types of cutting.

    For more information, contact:

    Caron Engineering, Inc.

    116 Willie Hill Rd.

    Wells, ME  04090

    207-646-6071

    marketing@caroneng.com

    www.caroneng.com


 Products

  • TMAC 3.0 - Adaptive Tool Monitoring System
    Caron Engineering's new adaptive tool monitoring system, TMAC 3.0, is a real-time tool wear and breakage detection system. TMAC interfaces directly with the CNC control to optimize machining and make real-time corrective adjustments during cutting....

  • TMAC is a real-time tool wear detection system that uses high-precision, multi-range sensors to determine if a tool is worn or broken. Caron Engineering sensors are 10 times more sensitive than other sensors on the market, allowing TMAC to cover a wider range of tools. TMAC has a separate high-speed processor that collects data at 200 times per second, and directly interfaces with any CNC control, to react instantly to wear and extreme conditions.

    TMAC 3.0 has been completely redesigned with an intuitive streamlined user-interface that offers numerous configurations for viewing tool monitoring and sensor data.  The TMAC system processor now houses its own web server, making the HMI (human-machine interface) browser-based, which enables real-time monitoring from any network connected device. Users (with assigned permissions) have live access to all TMAC systems on a shop floor from a single browser.  Securities and permissions can be customized for each user to assign system access based on their user role and job function.

    TMAC has an adaptive control mode that optimizes cutting with changing conditions due to wear, variations in material hardness, consistency, and depth of cut. Using a power sensor to monitor motor power, TMAC overrides the machine tool feedrate to maintain a constant spindle motor power during cutting. This enables TMAC to increase the feedrate with low power cuts and decrease with high power cuts, and as tools wear. No operator intervention is necessary when TMAC is monitoring and controlling, making it ideal for unattended operations. Users will see an immediate increase in productivity, extended tool life, and overall reduction in cycle time (up to 60%). Cycle time savings are most significant with hard and difficult to machine materials.

    In addition to power, TMAC monitors sensors for vibration, strain, coolant pressure and flow, and spindle speed. The newly enhanced HMI has expanded the monitoring capabilities with TMAC. Users can customize views to show up to 4 sensor channels simultaneously in a single view.  For example, the user can set up a single (split-screen) view to monitor power, vibration, spindle speed, and coolant for a specific tool and section at the same time; and have unique limits for each sensor and channel.  A user can create unlimited views to show data in a variety of ways, and easily toggle between views during monitoring.  Using a vibration sensor TMAC also monitors spindle bearing health, with the analysis initiated by calls in the CNC program.

    The TMAC data viewer and event log stores all cutting data and events. Any number of data files can be opened simultaneously to easily view graphical differences and allows overlaying cutting data to compare and analyze cuts.

    Learn More

  • DTect-IT - Sensor and Software Monitoring Suite
    The new DTect-IT sensor and software monitoring suite, originally developed to detect bar feeder vibration and analyze spindle bearing health, now offers expanded applications....

  • Caron Engineering’s DTect-IT was first introduced in 2016 as a product primarily used for detecting vibration levels and irregularities anywhere on a CNC machine tool or fixture; with featured applications of bearing analysis and barfeeder vibration detection (and correction).

    DTect-IT has become even more versatile since its inception, now capable of communicating with multiple sensors, including vibration, strain (to measure force), high precision power, and analog (which allows connecting any sensor with a 0 to ± 10 VDC analog signal, and 4 – 20 mA current signals). DTect-IT software has multiple analysis options allowing the user to monitor and scrutinize sensor data in various ways.

    Using limit analysis, the user can set limits to monitor any of the compatible sensors.  DTect-IT has a new learn mode to automatically set limits based on the acquired (learned) sensor data or limits can be set manually using adjustable sliders.  When a defined limit has been met or exceeded, alarms and notifications occur.

    Barfeeder vibration detection has been a widely used application with limit analysis. By attaching a vibration sensor to the barfeeder, limits can be set to detect excessive vibration levels due to imperfections in the bar.  DTect-IT can signal the CNC to reduce spindle RPM until the vibration levels are acceptable to make good parts or even stop the machine if extreme vibration levels are detected.  This application is greatly reducing scrap rates and decreasing spindle damage due to excessive vibration by detecting and compensating for imperfections in real-time instead of machining a whole (bad) bar of parts.

    With bearing analysis, DTect-IT analyzes the velocity and acceleration signatures of a vibration sensor (attached to the spindle) to monitor spindle bearing health. Results are displayed within 5 seconds, and reports are automatically generated and saved for future analysis. Using the built-in data viewer, users can trend bearing data over time to establish maintenance schedules.

    Fault detection analysis can be used with any sensor to identify an excessive condition, such as machine impact, overheating, extreme vibration, etc. DTect-IT recognizes when upper and lower limits are exceeded and records data on either side of the fault for analysis.

    The newest analysis option with DTect-IT is frequency analysis. DTect-IT can monitor the frequency levels of any sensor and set magnitude limits to monitor and detect anomalies within specific frequency bands.  Alarms and notifications are generated when magnitude limits (in decibels) are exceeded.

    The combination of sensor options and analysis options (of which multiple can be run simultaneously for each sensor), make the applications for this product almost limitless. Many of the more prominent applications, include the abovementioned barfeeder vibration detection and bearing analysis, but DTect-IT is also widely used to for tool wear and breakage detection, yoke strain detection, tapping operations, coolant and temperature monitoring, machine health, preventative maintenance, and more.

    DTect-IT offers a lot of functionality and features ideal for a smart manufacturing environment. It is best for monitoring up to four tools.  It can run as a standalone application or easily connects to the CNC to command start and stop variables. DTect-IT can set sensor levels and alarms with variables that can be used by the CNC part program to make adjustments. DTect-IT has a data collection analysis to collect raw data from any sensor (up to 62,500 data points/sec). 

    The latest release of DTect-IT includes a new analysis viewer.  All monitored data is stored and can be accessed via the DTect-IT Viewer for inspection, review, and analysis. The MTConnect compatibility allows users to interrogate sensor information on various levels and provides seamless communication with shop floor automation systems. 

    LEARN MORE

  • ToolConnect - RFID Tool Load Automation System
    ToolConnect is a tool identification system that eliminates human error and reduces setup time by automating the transfer of CNC tool data to (and from) the control. It is customized to the user's tool load requirements and process specifications.

    ...

  • Caron Engineering offers a retrofit tool identification and data management (ToolConnect) system that automatically reads and writes tool presetter data between the machine control and RFID tags embedded in tool holders. 

    This system uses a customized RFID read station and an intuitive interface tailored to the user’s tool load and unload process. The ToolConnect HMI displays all user-specified tool and process info, along with a tool image to easily verify that the correct tool is being loaded.  The system can automatically index to the correct magazine position for further error-proofing of the process on some machine tools.

    Improve Operator Efficiency

    Caron Engineering’s ToolConnect system can be added to nearly any machine tool as a means to provide a common user interface for every CNC machine on the shop floor, irrespective of builder. This alleviates the inefficiencies of using OEM-specific tool identification that each have their own unique user interface; which might require operators on the shop floor to be educated on multiple different systems, all largely performing the same function. Operators that use ToolConnect only need to be familiar with one type of system with the result being an increase of productivity on the shop floor.

    Flexible and Customizable Design

    Unlike the rigid specifications of OEM tool identification systems, ToolConnect offers a flexible design that can easily accommodate changes to a process. The system is built specifically to the customers’ requirements, from the (drag and drop) design of the UI to the overall process and functionality of the system. The infrastructure of ToolConnect allows processes to be adjusted and additional functions can be added at any time.  Updates can be made by a technician in the field or via remote access by a certified technician. Additionally, ToolConnect offers a large support network through Caron Engineering’s worldwide representation of certified systems integrators.

    Compatibility

    ToolConnect works with nearly any tool presetter that can write to an RFID tag.  ToolConnect easily adapts to new RFID systems, which OEM provided systems are currently not capable of doing.

    Benefits

    ToolConnect reduces setup time by automating the process of loading and unloading tools into the machine. As an added failsafe, if an operator tries to load an incorrect tool, or a tool in the wrong pot, ToolConnect will alert the operator. This system eliminates the initial in-machine tool measurement and manual entry of tool geometry and wear offsets, providing more chip cutting time. ToolConnect also removes the need for post processors between the tool presetter and CNC.

    LEARN MORE

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