Caron Engineering develops CNC machine optimization solutions that are essential for any Smart Factory. They are excited to introduce their newest Tool Monitoring Adaptive Control system…TMAC 3.0. TMAC monitors tools using customized sensors for power, vibration, or strain to measure tool wear. TMAC learns the cut, allowing the operator to visualize the actual cutting to make the necessary adjustments to run at optimum efficiency.
By measuring tool wear in real-time, TMAC will automatically expire a tool if excessive wear is detected (and can signal a redundant tool) or immediately stop the machine and retract the tool in the event of breakage. This direct interface with the CNC control allows machines to run unattended.
The new TMAC 3.0 offers an intuitive user interface designed to handle the complexity of the software while providing simplicity for the user. The web-based UI has completely customizable user views with a dynamic display that can be accessed from any device (including smart phones) and allows monitoring multiple processes and even multiple machine channels simultaneously.
TMAC can optimize almost any cutting operation but also mitigates specific manufacturing challenges with difficult to machine materials, such as hard aerospace components. Typically, programmers must plan for the worst material condition, which leads to lengthy cycle times and accelerated tool wear. This is especially true with aerospace components since they are machined from alloys and composite materials, and from either a casting or forging or single solid block of material. TMAC Adaptive Control overrides the machine tool feedrate to automatically make adjustments based on the cutting power load of the tool. Thus, TMAC is increasing the feedrate with low power cuts and decreasing with high power cuts and as tools wear. By making real-time adaptive control feedrate adjustments TMAC optimizes the entire cutting process, extends tool life, and reduces cycle time up to 60%.
TMAC collects a large amount of data for analysis. It utilizes a separate high-speed processor capable of quickly processing data from multiple different sensors including power, vibration, strain, coolant pressure, coolant flow, and spindle speed. With multiple sensor options and high speed processing, TMAC can monitor the total health and condition of the machine. Users can overlay cutting data to compare cuts, interrogate alarms and events, access historical tool wear data, inspect CNC position data, and even analyze bearing health with the bearing analysis feature. All Caron Engineering products are MTConnect compliant allowing seamless communication with OEE software.
Typical installation time for TMAC is one day or less. This can vary slightly depending on the number of sensor options and monitoring capacity the customer requires. Standard training is two days to learn the system, though more can be added at the customer’s request. There is also free online training for TMAC, which is also built into the software, so customers can have training and tutorials at their fingertips. Customers often see a ROI within the first three months of implementing the system.