- 1 -

NORDMANN Tool Monitoring

• Control-integrated tool monitoring for open CNC control panels

• Sensors for monitoring micro tools by the measurement of the acoustic emission

• Integrated acoustic work piece dimension control (patented)

• Gap elimination for grinding

• Non-contacting measurement technology(inductive and by radio waves)

• Acoustic emission measurement based on a jet of cooling lubricant acting as an acoustic wave conductor

Experience since 1989 in the field of tool monitoring and process control systems for

all types of cutting machine tools

Our program:

- 2 -

NORDMANN Central Locations

Nordmann International GmbH

8808 Pfäffikon, Switzerland

Nordmann GmbH & Co. KG

50354 Hürth, Germany

Manufacturing:

- Tool Monitor units

- Effective power units

- Acoustic Emission Processor units (SEP)

- Distribution and service south Europe

Headquarters:

- Sensor production

- Custom-made products

- Central of distribution service

- Coordination and distribution further branchoffices in USA, China, India and Korea

- 3 -

Where tool monitoring happens (examples)

Multi-spindle drill heads Automatic multi-spindle lathes CNC lathes Rotary cycle machines

Machining centers Dressing of grinding wheels Roll grinding machines Transfer lines

- 4 -

Functions of the Tool Monitor for turning, drilling and milling

Tool and machine protection

Quality assurance and avoiding of scrap

More work pieces per hour

▪ Tool breakage detection in the moment of the breakage

▪ Tool wear detection to prevent tool breakage

▪ Detection of incorrectly clamped work pieces.

▪ Detection of false blank dimensions.

▪ Toll wear detection to ensure the quality of the workpiece

▪ Machining time reduction through the option of increasing the cut value without danger

▪ Reduction in air cutting thanks to fast reacting detection of the start of the cut (main use is grinding)

- 5 -

References (Examples)The following list is a small selection of companies that trust Nordmann tool monitor systems.

We have sold more than 15250 systems worldwide (current status Oct. 2019). Our export share is 40%.

Machine tool manufacturer Machine tool users

* We are listed in the user requirement specifications of these companies

Atlas Copco

Audi

Austrian Airlines

Berger

BMW

BorgWarner

Bosch

Braun

Brueninghaus

Burgmaier

Christian Weber

Chopard

Continental

Daimler *

Danfoss

Delphi

Deutsche Star

Deutz AG

Dom

Erkert

EVVA

FAG

Fertigungst. Nord

Fischer Werke

Ford

Galsterer

General Motors

Getrag

Geze

GKN

Häring

Harley-Davidson

Heimeier

Hero Honda

Hewlett Packard

Harting

Hilti

INA

ITT

Keso

Lego

Lucas

LuK

Mahle

MAN B+W Diesel

Mesa

Motomak

NGK

Oberndörfer

Océ

Oerlikon Enka Tecnica

Opel

Philips

Quinn Scheuerle

Rexroth Star

Röhm

Schäffler *

Scheufele

Schneeberger

SFS

Siemens

SKF

Spicer

Stihl

Straumann

Textron

Thyssen Guss

TRW

Viega

Visteon

Voss

VW *

Winkhaus

ZF

Krause-Mauser

Kummer

Magdeburg

Meccanicanova

Mikron

Overbeck

Pfiffner

Precitrame

Riello

Sala

Schaudt Mikrosa

Schütte

Siemens

Spinner

Studer

T-Mech

Technica

UVA

Variomatic

Vimacchine

Witzig & Frank

Buderus

Carl Benzinger

Chiron

Citizen

Gildemeister

EMCO

Ernst Grob

Eubama

EWAG

Hage

Höfler

Hüller-Hille

Imoberdorf

Index

I.T.S.

Ixion

Kapp

Ketterer

Klingelnberg

Krause- Mauser

- 6 -

Car manufacturers place their trust in NordmannThe following car manufacturers have included Nordmann in their “ Process Monitoring“ Functional Specifications:

Nordmann was chosen on the basis of comparative evaluations in respect of measured value quality,

monitoring strategy, ease of use, operator acceptability, service response and price.

Other car manufacturer as Audi, BMW, Ford and GM (Opel) also use Nordmann, however without

explicit reference to that effect in a functional specification.

- 7 -

Configuration of a tool monitoring system

Effective power

and torque

Force

Acoustic and vibration

Tool length & work

piece position control

Tool position control

Ethernet

PC

NC control panel

Display with touchscreen

Tool Monitor

SEM-Modul-e

Measuring element Control device Visualization

Digital drive data

(torque, effective

power, current)

Profibus / Profinet

Digital

measurement

Analog measurement

and operating unit

Work piece dimension

control

- 8 -

In-process and post-process tool monitoring

In-process tool monitoring

Indirect control during machining

with effective power, cutting force or acoustic emission

Post-process tool monitoring

Geometric control of the tool cutting edge

before or after machining with buttons, light barriers

or similar devices

For:

- The measurement does not extend the production time.

- The machine is stopped at the moment of tool breakage.

- Relief of machine operator in terms of “ear to the process”

- Recognition of process errors through viewing

measurement curves

- No additional installations (e.g. swivel buttons)

required near tool.

-Wear-resistant sensors.

Against:

- Does not offer 100% detection reliability for all tools and

breakage types.

- Sometimes the breakage is only noticed at the start of the cut

of the next work piece, e.g. screw tap breakage control with

effective power and breakage at the moment of direction

reversal.

For:

- Sometimes higher break detection reliability.

- Normally easy to use.

Against:

- The measurement can extend the production time.

- The machine is only stopped after tool breakage, i.e.

after damage to the work piece or the machine or tool

holder due to breakage forces.

- Not all test methods are without wear.

Rule of thumb: Check tools during the process. Small tools may

also be inspected post-process or must be checked in part post-process.

- 9 -

Konzept Tool Monitor SEM-Modul-e

• für alle Maschinentypen (z. B. CNC-Drehm., BAZ, Rundtakter, Mehrspindler, Schleifmaschine)

• für alle Sensoren (z. B. Kraft, Leistung, Schall, Laser)

• für alle Überwachungsstrategien (Hüllkurven, statische und dynamische Auswertung etc.)

Nur ein System mit nur einer Bedienerführung für alle Maschinentypen

Einer für Alle

Identische Oberfläche

Identische Bedienung

Nordmann-Display

CNC-Bedienfeld (hier: Sinumerik)

- 10 -

Functions of the Tool Monitor for turning, drilling and milling

Tool and machine protection

▪ Tool breakage detection

▪ Tool wear detection

▪ Collision detection

▪ Unbalance check

More work pieces per hour

▪ Machining time reduction through the option of increasing the cut value without danger

▪ In-process breakage detection saves additional testing time

▪ Reduction in air cutting thanks to fast reacting detection of the start of the cut (main use is grinding)

▪ Triggering withdrawal of the tool when completion of the cut is detected (through holes, cutting through half-finished products)

Quality assurance and avoiding of scrap

▪ Detection of incorrectly clamped work pieces.

▪ Detection of false blank dimensions.

▪ Dimension control of the finished part inside the machine.

▪ Envelope curves detects process deflections and can thereby avoid of scrap

- 11 -

Straight limits Envelopes

✓ Tool breakage detection

✓ Cut start recognition (for rapid air cutting monitoring,

especially when grinding)

✓ Special minimum limit for checking whether tool is available

✓ More precise tool breakage detection that with straight limits

Specifically for monitoring mult-spindle drill heads with

effective power measurement in conjunction with smooth

envelope matching (Autolearn)

Application of straight limits: Application of envelopes:

“Straight limit” over curve

“Straight limit” under curve Minimumlimit

Curve section to calculate the mean height

Upper

envelope

Lower envelope

Above mean height

Below mean height

Curve section to calculate the mean height

Monitoring strategies and limit values for measured curves

- 12 -

Limit over mean height

Trend display of the mean height (tool wear)

For better tracking of the behavior of the "mean height" across a larger number of workpieces, it can be represented as a

"trend" over the number of machined workpieces. This makes it easier to determine whether a tool effects an even

increase of the measured values with the number of workpieces produced, or whether it is necessary to add an averaging

of the "mean height" across several workpieces.

Limit over

mean height

Mean height

of last work piece

Tool blunt

New (sharp) tool

0

3

5

6

[kW]

2

1

4

- 13 -

Rectified dynamic portion (option)Dynamic portion (option)

Monitoring jump-like changes and waviness

Use of dynamic portion: Use of rectified dynamic portion:

✓ Breakage recognition when turning with offset and hardness

fluctuations, when a sudden measured value increase needs

to be monitored independently of a measured value drop.

✓ Recognition of out-of-true running of a milling cutter due

to individual tooth breakage.

✓ Chatter and undulation recognition during grinding.

✓ Breakage recognition when turning with offset and

hardness fluctuations.

Upper envelope

Lower envelope

Upper envelope

Above mean height

- 14 -

Gliding Reference Limit

WLM-3

Application example multi-spindle drill head:

Allows for breakage monitoring of several drill bits driven by a common motor via

effective power measurement.

Original problem: Changes in measured value height due to the breakage of a single

drill bit are smaller than changes due to the wear of all drill bits. Thus, fixed envelopes

are not violated.

Solution: Gliding adjustment of the envelope limits from workpiece to workpiece to the

changes in measurement curve height due to tool wear. This allows for a much smaller

distance between envelope and measurement curve.

The envelope follows, at a percentage distance (e.g. ± 5 %), an "averaged

measurement curve" obtained by averaging across the last workpieces.

All 6 drill bits sharp All 6 drill bits half blunt All 6 drill bits blunt1. Workpiece 250. Workpiece 500. Workpiece

502. WorkpieceAll 6 drill bits blunt, 1 drill bit breaking

Fixed envelopes

Sliding envelopes continually readjust from workpiece to workpiece.

1

2

1

-5%2

2

2

1

1

2

2

1

1

22

1

11

3

2

+5%

breakage!

3 Averaged measurement curve (temporary enlarged after changing a new sharp tool)

3

- 15 -

Tool Monitoring Requirements

• Few operating steps/options

• Few operating controls (“buttons“)

• Few indicator readings (black box)

• Good measured values even with small tools

• Recognition of even most minimal tool breakages

• Reliable wear detection

• Irrespective of working material hardness or offset

fluctuations

• Monitoring of individual drill bits in multi-spindle drill heads

User-friendliness (general view) Sensitivity

Constant conflict between user-friendliness and sensitivity

- 16 -

Operator-friendliness and sensitivity “under the one hat“

• Self-explanatory pulldown menus

• Operator and task-related switching off (hiding) of unneeded

menus

• Measurement curve display shows process errors at a mere

glance

• Graphic settings option of limits using the mouse or touch

pen in touch screen (edit image)

• Automatic limit value correction with acknowledgement of

repeated false alarms

• Sensors for monitoring the smallest tools (to Ø 0.05 mm)

• Envelopes as limits with or without automatic adjustment

to creeping measured value changes

• Evaluation of static and dynamic signal sections each with

its own measurement curve

• Wear detection with mean measurement curve height,

averaged over several workpieces

SensitivityOperator-friendliness

- 17 -

Manual adjustment of the envelope curves at the touchscreen by finger

- 18 -

Die Grenzen sollen unverändert bleiben

Alle Grenzen sollen sich

an die Messkurve anpassen

Die verletzte Grenze soll sich automatisch

an diesen Alarm anpassen

1.) Grenzen anpassen?

Bitte wählen Sie aus:

Dieses Programm neu lernen

5.0

12.5

20.0

27.5

35.0

42.5

50.0

0.0 0.0 0.0 0.0

0.0 1.59 3.19 4.78 [sec] 7.970.0

1.0

2.0

3.0

4.0

5.0

6.0

[kW]

0.0 1.59 3.19 4.78 [sec] 7.970.0

1.0

2.0

3.0

4.0

5.0

6.0

[kW]

Automatische partielle Grenzwertkorrektur

nach falschen Alarmen (SEM-Modul)

1.) Messkurvenanzeige beim Alarm

Vorteile der autom. Grenzwertkorrektur

Die Hüllkurve wird nur bzgl. der

Störung durch den Spänestau

angepasst.

Eine bis dahin vorgenommene

Optimierung der Grenzwerthöhe

wird dabei nicht gelöscht.

Spänestau beim Bohren

führt zu Fehlalarm

Autom. Korrektur der Hüllkurve entspre-

chend dem Ausreißer durch Spänestau

2.) Möglichkeiten der Alarmquittierung

3.) Ergebnis nach Alarmquittierung

ALARM

- 19 -

Bedienung über Pulldownmenüs und Softkeys

Klar strukturierte, bedienerbezogene

Pulldownmenüs

Innerhalb der Menüs werden alle

Einstellungen erläutert.

Bedienerbezogene Softkeys für

häufig benutzte Funktionen

[kW]

- 20 -

Benutzerverwaltung (Group Management)

Bedienerbezogene Nutzungsrechte

• 4 Bedienergruppen mit sinnvoller

Standardkonfiguration

• Möglichkeit der Änderung

dieser Konfiguration kundenseitig

je nach Bedarf

Erstellung benutzerbe-zogener

Softkeys für schnellen Zugriff auf

Menüs

- 21 -

WLM-3

WLM-3

PDA

SEA-Mini(acoustic emission measurement)

WLM-3S(three phase effective

power measurement)

WLM-3S(three phase effective

power measurement)

SEH(acoustic emission

measurement)

Possible sensor positions for tool monitoring in CNC lathes

cooling

lubricant

- 22 -

SEH

Work piece

WLM-3

APS-L

(acoustic emission

measurement via jet of

cooling lubricant as acoustic

wave conductor)

SEH

cooling

lubricant

Jet nozzle

coolant jet as barrier (patented)

WLM-3S(three phase effective

power measurement)

Possible sensor positions for tool monitoring in machining centers

- 23 -

SEH

Kühlschmierstoff

SEA-Mini

WLM-3SWLM-3

SDS

(acoustic

emission

measurement)

(coolant jet as

barrier)

cooling

lubricant

(acoustic emission measurement)(acoustic emission conductor made of spring steel)

Possible sensor positions for tool monitoring in transfer lines and rotary transfer

machines

(effective power

measurement)

WLM-3SWLM-3 (effective power

measurement)

- 24 -

SEA-MiniSEH

Vors

chub

WLT

PDA

(acoustic

emission

measurement)

(feed force

measuring via

the bending of

the rocker arm)

(feed force

measuring via the

compression

of the feed rod)

(acoustic

emission

measurement)

cooling

lubricant

(work piece length control measurement)

Possible sensor positions for tool monitoring in multi-spindle automatic lathes

DMS-Kralle

- 25 -

Tool monitoring system SEM-MODUL-e connected with the Profibus in

sinumeric controls 840D(sl)

Terminal block for 8 additional

sensors for measuring force,

acoustic emission, pressure,

path distance, laser light

shadowing and ultrasonic drill

length control

Exchange of control

signals and transmission

of actual values for

power, torque and

current (8, 16 or 24

spindle and feed drives

of 1 SEM-MODUL-e can

be evaluated)

Software

for viewing

Tool Monitor

SEM-MODUL-e

Profibus DP

Ethernet

Siemens-Sinumerik-HMI

NCU 7x0

Control

software with

additional

technological

function

Siemens

CNC-Unit

- 26 -

Modern design with „Apps“

- 27 -

Visualisation of the Tool Monitor SEM-MODUL-e on aSiemens Sinumerik 840 D

- 28 -

New Tool Monitor SEM-MODUL-e

“-e” for:

• evolutionary

• easy operation and ergonomic

• extremely powerful

• efficient production of monitored

machine

• ethernet connection

• extended measurement curve display

(multiple measurement curves

simultaneously)

New features relative to the last SEM-Modul:

• Displays up to 36 measurement curves in parallel (here: 4 measurement curves), can monitor up to 50 measurement curves

in parallel

• Allows monitoring of up to 4 time-independent operating machines (or stations)

• 3 Profibus interfaces for recording internal drive data and for exchanging control signals

• Visualisation and operation on a 10.4” touchscreen (previously SEM-Modul: 5.6"), or on a tablet via WLAN (with VNC viewer)

• Fully networkable and fully integrated into the intranet or Internet, including remote access

• Simple data backup via Ethernet or USB stick

- 29 -

SEH (Standard)SEH (Maxi) SEH (Mini)

SEH Acoustic Emission Hydrophon

- 30 -

Sound emission hydrophone SEH for acoustic emissions from rotating drills

- 31 -

Sound emission hydrophone SEH for acoustic emissions from rotating drills (former patent Nordmann DE 36 27 796)

- 32 -

Wirkleistungsmessgerät WLM-3S

„S“ steht für:- Per Steuersignal veränderbare Verstärkung für den Strom-Messwert

- Strom-Übersteuerungsanzeige warnt bei zu hoher Verstärkung des Strom-Messwertes

- Höhere Stabilität des Messkurve (weniger Welligkeit und Rauschen)

- 33 -

Spindle power P40%DR [kW]

0

1

2

3

4

5

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Monitorable drill diameters for good motorspindles

D [mm] ≥P40%ED [kW]

2

Monitorable minimum drill diameter

Drill

dia

me

ter D

[mm

]

- 34 -

Vergleich analog gemessener Wirkleistung

mit internen Antriebsdaten

Wirkleistungsmessgerät WLM-3S Wirkleistungsmessgerät WLM-3

Per Synchronaktion aus Sinumerik

840D gewonnener WirkleistungswertPer Compile-Zyklus aus Sinumerik 840D

gewonnener Wirkleistungswert

- 35 -

Vergleich digitale Antriebsdaten / analoge Wirkleistungsmessung

bzgl. der Auswertung schneller Messwertveränderungen

Digitales Drehmoment per Profibus vom

NC-Rechner an Tool Monitor übertragen

Dreiphasen-Wirkleistungsmessung

(gemessen mit WLM-3S)

• Werkzeug: Bohrer Ø 8 mm

• Maschine: Index ABC Speedline

• Messung: z-Achse

Die direkte Messung der Wirkleistung ist der Auswertung des

digitalen Drehmoments bzgl. der Erkennung schneller

Messwertveränderungen (Bruch, Rattern) überlegen!

Rattern nicht sichtbar

Fazit:

Prozess:

Rattern sehr

gut sichtbar

- 36 -

Measuring point : 01

Cut: 01

Effective power

Measuring point : 01

Cut: 01

Effective power

Measuring point : 01

Cut: 01

Effective power

Measuring point : 01

Cut: 01

Effective power

Evaluation of the dynamic of the effective power to detect milling head tooth

breakage

Milling head dull, but no tooth broken 1 milling head tooth broken, breakage of other

pieces during cutting

Dynamic

Dynamic portion of the effective power

Dynamic

Effective power of the spindle motor

8 blade cutter

head of

Ø 80mm

- 37 -

Aco

ustic e

mis

sio

n

Time

(acoustic

emission

measure-

ment)

SEHDrill

Ø 1mm

Coolant jet

as a acoustic

conductor

Chip removal signal measurement with an acoustic emission hydrophone

on the drill

- 38 -

Breakage

Measuring point : 01

Cut: 01

Acoustic

tool burst (0,2mm)

(acoustic

emission

measure-

ment)

SEHDrill

Ø 1mm

Coolant jet

as a acoustic

conductor

Measured value of the acoustic emission hydrophone during breakage of a

0.2mm piece of a conic nozzle drill

- 39 -

Drill dull

Breakage

The last 4 holes drilled with the increase in

measured values and breakage

Breakage

Drill dull

Last normal

hole

drilled

Time (s)

Ac

ou

sti

c e

mis

sio

n (

dB

)

Time (s)

Ac

ou

sti

c e

mis

sio

n (

dB

)

Development of acoustic emission until drill breaks

Example: Drill with Ø 3mm acoustic emission recording from machine table with SEA

- 40 -

Acoustic emission measurement (sensor SEH) directly on the tool with a jet of

cooling lubricant as acoustic wave conductor in various machines

Vierspindliger

Gewinde-

bohrkopf

Sensor SEH: Körper-

schallaufnahme

über einen Kühl-

schmierstoffstrahl

am Werkstück oder

Werkzeug

Machining center

CNC lathe

Multi-spindle lathe Rotary cycle machine

SEH

Drill Ø 1mm

SEH

Lathe tool

SEH

Drill Ø 0,8mm

Four spindle

thread drill head

Sensor SEH: Acoustic

emission measuring on the

work piece with a jet of

cooling lubricant as

acoustic emission

conductor

- 41 -

Acoustic emission with the jet of cooling lubricant from the work piece

Measuring point : 01

Acoustic

Measured value of the acoustic emission hydrophone during breakage of a

3mm drill in a 6-spindle drill head

- 42 -

Vertical stream of oil

as acoustic conductor

(approx. 30 cm long)

Acoustic emission

hydrophone SEH

work piece

Breakage on

the roller

Detection of breakage on toothing hammer

- 43 -

Detection of flaking on rolling tools (Profiroll)

Alarm display of acoustic emission signals on breakage:

Breakage peak

Breakage

Breakage

Expansion options:

Force measurement with strain gauge claw for double

protection!

Evaluation method: Display of the increased dynamic

portion of the rolling force due to break out during rolling of

the next work pieces.

- 44 -

monitored

lathe tools

SEA-Mini(acoustic

emission

measurement)

SEA(acoustic emission

measurement)

Acoustic emission measurement on tool with SEA sensor

Acoustic emission sensor on the tool holder in an

automatic multi-spindle lathe

Acoustic emission sensor directly on the tool

during collector turning

- 45 -

Vorschubkraftmessung in kurvengesteuerten Mehrspindeldrehautomaten

mittels Dehnungsaufnehmern auf den Kulissenhebeln

BDA-Kralle

DMS-Kralle

PDA

Messprinzip: Dehnungsmessstreifen

Befestigung: Anschrauben M5 (5 Nm)

Einsatz bei Erfordernis einer hohen

Empfindlichkeit bei längerer Messungs-

dauer

Messprinzip: Piezoelektrisch

Befestigung: Aufkleben

Einsatz bei Erfordernis einer

höchsten Messempfindlichkeit bei

kurzer Messungsdauer und bei

nicht bekannter oder variabler

Kraftrichtung

Messprinzip: Wirbelstrom

Befestigung: Anschrauben M5 (3 Nm)

Einsatz bei geringer Anforderung an die

Messempfindlichkeit bei längerer

Messungsdauer

Messempfind-

lichkeitTemperatur-

driftabstand

Maximal

messbare

Dehnung

- 46 -

monitored drill

BDA-Kralle(feed force measurement)

Force measuring on the feed rod in multi-spindle automatic lathes

- 47 -

✓ Assembly surface does not need to be prepared

✓ Independent of the torque from the mounted screw (M5)

✓ Highly sensitive (1 nanometer)

Advantages of the BDA-Kralle strain gauge

- 48 -

Strain and force sensor PDA

Benefits:

• Fixed with adhesive (instead of screws)

• Same sensitivity in all directions, so it is not necessary to know the exact direction of the strain to be measured

• Tool-oriented attachment possible thanks to compact design (diameter 16 mm, height 8 mm)

- 49 -

Werkzeugbruchkontrolle für das Drehräumen von Kurbelwellen

Messprinzip:

Kontrolle der Schnittkräfte über eine Dehnungsmessung am Fuß des Revolverkastens

Überwachungsstrategie zur Schneidenbruchkontrolle:

Gleitende Anpassung der Hüllkurvengrenzen von Werkstück zu Werkstück an die Veränderung der

Messkurvenhöhe infolge Werkzeugverschleiß, Vorbearbeitung, Werkstoffhärte, Aufmaß und Temperatur. Damit

bleibt der Abstand der Hüllkurve zur Messkurve relativ konstant. Die Hüllkurve orientiert sich hierbei mit einem

prozentualen Abstand an einer “Gemittelten Messkurve”, die durch Mitteln über jeweils die letzten Werkstücke

gebildet wird.

Gebrochene

Schneidplatte

Dehnungsaufnehmer

DMS-Kralle

Gemittelte Messkurve als Basis für

die gleitende Anpassung der Hüllkurve

Aktuelle normale Messkurve

(Schneide in Ordnung)

- 50 -

Was Werkzeugüberwachung mit einer Kraftmessung leisten kannam Beispiel des Ausbruchs von CBN-Platten beim Hartdrehen

Bruch

Bruch

Bruch

Bruch

Dynamischer Anteil

Dieser Bruch hinterließ im Werkstück

einen Durchmessersprung von 7µm

(= Stufe von 3,5µm)

Passivkraft von Bruch 1

Dieser Bruch hinterließ im Werkstück

einen Durchmessersprung von 10µm

(= Stufe von 5µm)

Passivkraft von Bruch 2

Dynamischer Anteil

Originalmesswert Originalmesswert

- 51 -

Multi-spindle drill head with toque sensor

Torque sensor

DMA

With the DMA, the torque acting on its measuring

shaft can be measured bidirectionally both at

standstill and during rotation.

The signalling wave, the non-contact signal

recording of this wave, as well as the signal

conditioning are integrated.

Measuring principle / applications

Drilling spindles

to be monitoredBenefits

- Bidirectional measuring range (2.5 – 500 Nm)

- High repeatability (<± 0.1%)

- Low current consumption during measuring operation

(<10 mA)

- 52 -

Control of the crackling noise when the

corindon particle impacts on the deflector

plate in front and in back of the work piece.

Breakage control for honing on Hurth

Measuring principle:

Sensor:

Acoustic emission sensor NF-SEA

- 53 -

Principle of acoustic work piece dimension control (Patent Nordmann DE 197 15 634)

Work piece (rotating) Acoustic emission sensor

(SEA mini)

Upper tolerance limit of the work piece

= path of movement of the test tool

Test tool

(turning cutting plate) SEA mini acoustic

emission sensor Principle:

As soon as the turning tool touches the surface

of the rapidly rotating work piece, a frictional

sound = contact signal is generated

Benefits:Turret box

✓ Robust, because there is no need for sensitive buttons

✓ Repeatability accuracy 1 μm

✓ inexpensive

✓ fast

- 54 -

Workpiece measurement check (patented procedure) using the example of a

thread check

Test cut (turning tool)

Turned contour to

be checked

(e.g. thread)

Work piece

measurement check

via friction acoustic emission

on a test cut on the turned

work piece

- 55 -

"Slipping"

on work piece

without additional feedIncre

ase b

y

40 d

B =

facto

r 100!

1μm 1μm 1μm 1μm 1μm

Measured value during scan Scan in x-direction (lathe tool on rotating work piece)

Acoustic work piece dimension control

- 56 -

Work piece length control in the multi-spindle lathe using the WLT length

sensor

Measurment method:

The work piece length sensor checks in the multi-spindle lathe between two sites along the workpiece as

workpieces continue to cycle. Here the work pieces touch the convex forward edge of a spring-mounted

measuring piston which is pressed backwards accordingly.

Advantages:

- Detects insufficient feed of the bar

- Detects whether work pieces have been pressed into chuck by machining

- Considerably more robust thand the BDA-Pilz work piece length sensor including specified breakage point in

fixing screw

- Easily adjusted to different work piece lengths as mounted on a rail

workpiece WLT length

sensor

- 57 -

Closed process diagram for grinding and dressing

Grinding

- Controlled switchover air cutting/roug

turning/finish machining/spark-out/rapid

withdrawal

- Control of centering with reference to even

wear on the grinding disk when gear grinding

- Feed control to maintain constant grinding

pressure and spring-off

- Touch dressing tool wear monitoring

- Detection of vibration of the dressing tool

- Control of the starting effective surface

roughness of the grinding wheel

- Reducing air cutting

- Collision detection

- Wear detection

- Concentricity control

- Imbalance monitoring

- Detection of first contact to compensate for

temperature expansion and wear of the

dressing tool and grinding wheel

- Touch dressing monitoring

Basic tasks Basic tasks

Sophisticated

Dressing

Sophisticated

- 58 -

SEA-Mini

RSA

SEH

SEA-Mini

WLM-3S

WLM-3

(acoustic emission measurement)

Possible sensor positions for monitoring grinding machines

(acoustic emission measurement)

(acoustic

emission measurement)

(acoustic emission

measurement)

(effective power

measurement for spindle

and feed drive)

cooling lubricant

- 59 -

Sharp

a

b

a

Dull

d

c

d

c

b

Grinding wheel

Time

1

2

34 5

6

1

2

3

4

5

6 Rapid reverse

Spark out

Finish machining

Rough turning

Air grinding

Rapid Feed

a

b

Time

Time

Ac

ou

sti

c e

mis

sio

n

Eff

ec

tive

po

we

r o

r n

orm

al fo

rce

Sta

tic

po

rtio

n

Grinding wheel

Time

Time

Ac

ou

sti

c e

mis

sio

n

Dyn

am

ic p

ort

ion

Limit values on the wear and process monitoring / examples:

a Limit for process degeneration (e.g. collision in rapid travel)

b Wear limit (monitoring of the mean height of the measurement curve)

c Limit for wear, waviness, and chatter

d Functions of this limit like c

(monitoring the mean height of

the dynamic portion of the measurement curve)

Ac

ou

sti

c e

mis

sio

n

Eff

ec

tive

po

we

r o

r

no

rma

l fo

rce

Signal from Tool Monitor

to switch to grinding feedCollision limit

Signal from Tool Monitor

to switch to rapid reverse

Ac

ou

sti

c e

mis

sio

n

Dyn

am

ic p

ort

ion

Signal from Tool Monitor

to switch to finishing feed

Fe

ed

pa

th

Examples for control and monitoring functions during grinding

- 60 -

SEH

1.2.

3.

RSA

RSA-Ring(consisting of

sender and

receiver)

RSA-2(transmit

measuring value

via spindle)

(consisting of

sender and

receiver)

Dressing

cup wheel

Dressing form roller

(acoustic

emission pickup

via jet of cooling

lubricant)

Grinding wheelGrinding wheel

Time

Touch dressing monitoring on

the profiled grinding wheel shown:

Aco

ustic e

mis

sio

n

1st

segment

2nd

segment

3rd

seg-

ment

Envelopes

(tolerance band)

Different contactless sensors for measuring acoustic emissions at dressing

- 61 -

Spark-

limit

0,5 µm1 µm 1 µm

Measuring point: 01

Acoustic

Dressing ring

SEH

Acoustic emission picked up from the dressing ring with a jet of cooling

lubricant to compensate the temperature expansion

Acoustic emission pickup with a jet of cooling lubricant (Sensor SEH) from the dressing ring for very small feeds

- 62 -

Rotating acoustic emission sensor RSA-2 for the rotor of the „Kaiser spindle“

SensorSensor

Sender

RSA-2 mounted in the Rotor

Rotor

Sensor

Rotor

Sender

Sender

- 63 -

Measuring curves of the sensor RSA-2 in the rotating dressing roll spindle for

dressing the seat contour (injection nozzle grinding)

Dressing the seat area of the grinding wheelDressing spindle with integrated RSA-2

Dressing roll

Dressing spindle

(Kaiser) with

integrated

RSA-separated

- 64 -

Examples of ring-shaped acoustic emission sensors

with non-contact measured value transmission (RSA ring)

RSA ring, example 1 RSA ring, example 2

Rotating acoustic emission

sensor and sender

RSA ring receiver RSA ring receiver

Rotating acoustic emission

sensor and sender

Distance between sender and receiver 0.5 to 2.0 mm: Mounted in injector grinding machine

Rotating acoustic

emission sensor

and sender

Rotating acoustic emission

sensor and sender

Work piece

(Injector)

RSA

ring receiver

Receiver

- 65 -

Measuring curves of the sensor RSA-Ring at dressing and grinding injection

nozzles on UVA grinding machines

Grinding of the plane

face

Grinding of the seat

Dressing the drill hole grinding disc Grinding the drill hole

- 66 -

Tool Monitor SEM-B3

• Kontakterkennung Schleifscheibe/Werkstück mit Vorschubumschaltung zum

beschleunigten Überbrücken des Luftschleifens in Verbindung mit Körperschall-

oder Wirkleistungsmessung.

Häufigste Anwendung:

Schalttafeleinbaugerät mit Digital- und Leuchtbandanzeige der Messwerte

• 4 separate Grenzwerte, die auf Über- und Unterschreiten reagieren

• 5 Optokopplerausgänge

• Einstellbare Glättung des Messwertes

- 67 -

✓ Extensive sensor palette for the most divergent measurement values and areas of application. Therefore even diffficult

monitoring tasks can be solved (e.g. miniature tools, multi-spindle drill heads, machining in hardened material, grinding with the

smallest abrasive pencil, machines with many work stations, etc.)

✓ Upgradable as unified system on all machine controls, independent of type and year of construction, whether with or without

PC as a work station.

✓ Universal Profibus, Profinet and ethernet interface, configurable for all machine controls that can transfer internal driving

data

✓ Particularly good monitoring strategy for the recognition of the smallest breakages with turning, drilling and cutting

✓ Wear monitoring basically included in the system without extra charge.

✓ Highly user-friendly through clear menus, graphic adjustment of the limit values and automatic envelope correction

✓ Development, production, sale, mounting and service all from one company.

✓ Service worldwide and quick on-the-spot support

Why do most new users decide on Nordmann tool monitoring?

- 68 -

Reduce costs and increase productivity

by using Nordmann Tool Monitors(Sheet 1)

Main potential Basic functions of the Tool Monitor Potential savings

Work piece cost reduction of tool costs

• Longer tool change intervals due to detection of early wear

• Possibility for economic regrinding due to timely tool change

• Option for safe experimentation with different types and shapes

of tools

• Possibility of using cheaper tools, as premature end of service

may be reported

• Prevention of tool breakage and consequent "clearing" of the

tools following processing

2 - 8%

0 - 5%

5 - 15%

10 - 20%Costs down

0 - 3%

Increasing the utilisation of the

tool machine (resulting in fewer

tool machines required)

the machine cost plus the production

costs and the operator costs

• Possibility of unattended breaks run or production in a partially

supervised 3rd shift.

• Lower main time per part due to possibility to safely test higher

cutting speeds and feed values.

• The measurement curve reveals early switchover points from

express to work feed

• Trouble-free operation by avoiding breakages and "clearing" of the

follow-up stations

• Gap elimination: Reduction of the main time by driving with higher

feed speeds up to the beginning of the cut (especially during

grinding)

2 - 8%

0 - 5%

Productivity up

0 - 7%

5 - 15%

10 - 20%

- 69 -

Reduce costs and increase productivity by using Nordmann Tool Monitors(Sheet 2)

Main potential Basic functions of the Tool Monitor Potential savings

Avoidance of rejects and

rework

the machine cost plus the production costs,

operator costs and raw material costs

• In-process work piece dimension control with pneumatic measuring

probes or with a turning tool as a probe (acoustic touch detection with

the sliding noise on the rotating work piece)

• Detection of low stock or short parts, which causes an immediate stop

of the machine or activation of a scrap gate

• Improvement of the surface quality by chattering detection

• In-process tool wear and break control with immediate stop.

• The visualisation of the process on the monitor often reveals

irregularities simply by looking at the measurement curve

Productivity

0 - 5%

0 - 2%

Costs 0 - 2%

0 - 3%

0 - 3%

Protection of the machine tool the acquisition cost of the machine tool

0 - 20%• Avoidance of machine fire (when using cutting oil)

• Protection of the machine when large tools break or during a crash 2 - 10%

Avoiding complaints about

sorting out bad parts • Detection of short parts based on other process irregularities and their

sorting via a scrap gate controlCustomers aren’t lost!

- 70 -

costs

savings

Costs/savings by the use of a tool monitoring system

- 71 -

Thank you for your attention!