Tuesday, November 5, 2024
The push for advanced automation in manufacturing has led Luxembourg’s CERATIZIT, in collaboration with Austria’s Materials Centre Leoben (MCL), to develop a more effective tool monitoring system aimed at improving productivity and reducing damage during machining processes. Over the past three years, their research under the ‘SmartDrilling’ project has focused on creating a reliable, adaptable monitoring system for drilling tools.
Automated tool monitoring is complex, especially given that even small changes — such as new material batches or different machine types — can impact tool lifespan. CERATIZIT’s current CERAsmart ToolScope system helps high-volume users by tracking tool force, current, and wear over time. However, for manufacturers with more varied, low-volume production, this solution can be cumbersome due to the need for frequent reconfiguration when processes change.
In response, the ‘SmartDrilling’ project has developed models and methods aimed at reducing reliance on extensive “run-in” periods to predict tool life. By analyzing common drilling processes, the project has advanced the data exchange between machine tools and operators, paving the way for a ‘Tool Condition Monitoring System’ that can assess tool wear and damage in real-time. This system relies on segmented sensor signals processed through specialized software, allowing it to detect only the signals most relevant to tool condition.
The SmartDrilling system’s data analysis algorithm provides continuous updates on tool condition and issues an audible alert before a tool reaches a critical damage state. This functionality allows a single operator to manage multiple machines and optimize manual intervention, loading, and maintenance schedules efficiently.
While CERATIZIT and MCL acknowledge that there is still work to be done before the system is market-ready, they highlight the project’s success in increasing efficiency for metal-cutting processes. They anticipate that the economic benefits of the Tool Condition Monitoring System will boost competitiveness for manufacturers by reducing tool downtime, improving production quality, and avoiding costly machine damage. In addition to economic advantages, the system is expected to contribute to environmental sustainability by ensuring tools are reconditioned in a timely manner and minimizing workpiece scrap.
With these developments, CERATIZIT and MCL’s tool monitoring system marks a significant step toward fully automated, efficient, and environmentally friendly machining solutions.
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