1. Caron Engineering Inc. was started in 1986 by founder and
PresidentRob Caron, PE, a licensed professional engineerWe have a
strong electrical engineering background in both hardwareand
software designOur focus has always been to enhance the ability of
any CNC machine byproviding advanced technology that can be added
to existing machinesThis advance tool monitoring and adaptive
control system wasfirst developed by Caron Engineering Inc. in
1989We have continued to enhance the product over the years
usingour extensive CNC control experience and the excellent
feedbackfrom our customersTMAC is now a world class system allowing
customers to betterunderstand and control their cutting tools
2. Maximizes tool life by monitoring power, not guessing
withcycle count or time in cut Reduces cycle time with Adaptive
Control Immediately stops any CNC machine and retracts the
spindlewhen a tool breaks to minimize damage Newly developed multi
process technology can monitorseveral cutting programs
simultaneously Ability to monitor extremely small tools (0.1mm)
with severalavailable sensor types Increase unattended lights out
operation with remotenotification of alarms Has the ability to use
power, strain and vibration sensors 3. Spindle MotorMeasures true
powerElectrically sums the currentand voltage referenceProvides a
0-10 Volt signalrespective of the powerCan be set to any power
range Spindlefrom 2-90 HP (1.5-67 kw) Drive(standard) 4. Power is
linear over the range of the motor,providing a very stable and
accurate indicator ofspindle motor Current, is non-linear over the
range of themotor due to power factor Most tool monitors provided
by machine toolbuilders measure current KW(HP) AMPSPower6 30Current
(Amps) 5 25 4 20 3 15 2 10 1 5 0 0 0%50% 100%Motor Load 5.
1205HPRange 6. Monitors true power instead of current as mostCNC
load monitors do Measures the power of a new tool during a cut
Determines whether a tool is worn or brokenby comparing the cutting
power to userprogrammed limits Adaptive control overrides the feed
rateautomatically to maintain constant powerduring cutting 7. TMAC8
works on the simple concept that the power used by a toolincreases
as it gets dull Retract the tool For a tap (somemachines) unwind
outPowerof material Send email or textExtrememessage to
WearEappropriate person X Stop after cuttingLearnedW T Call
redundant tool E R A E Not enough powerUndercut M was achieved R E
Any action that can be taken for WearPart # 1 10 15 20 25 28 29 and
Extreme limits 8. A machine like this can have (3)tools cutting
simultaneouslyrequiring (3) separate monitoringprocesses 9. The
TMAC-MP system was designed to run in the Linuxenvironment
providing a very expandable system Each TMAC process is initiated
by running an instance of a TMACapplication, allowing any number of
TMAC processes to be spawned Sensors can connected via Ethernet,
USB, RS232, Analog or digital The sensor processes can also be
expanded and communicate allsensor data to a common shared memory
area Digital and Ethernet I/O are also expandable and communicate
toand from shared memory Using the shared memory scheme, any TMAC
process can look atany sensor and communicate to any I/O (digital
or Ethernet) 10. Any process can be adaptivelycontrolled with
TMAC-MPAdaptive control allows the user toprogram or learn a the
power foreach tool and the system will adjustthe feedrate to
maintain this level.This technique especially useful forthe milling
tools but can be usedon all types of tool. It can reducecycle time
and extend tool life 11. The system can have our standard
multi-range power sensor for eachspindle motor on the machine. This
includes live tooling as well.The power sensor changes its
sensitivity based on how light or heavythe cut is for each tool6.03
HP Cut 0.007 HP Cut 12. New sensors are available for TMAC-MP Micro
Tool strain gauges Allow very small tools to be monitored (0.1mm
drill) Can monitor very small boring bars taking light cuts
Embedded in the tool holder Static (non-rotating) tools only
Accelerometers Monitor vibration in (3) axes Small footprint allows
easy mounting Useful for monitoring Spindle bearings Bar vibration
Machine impact Tool vibration Also includes a temperature sensor
13. All micro tools are hardwired toTMAC-MP and are embedded in
thetool holder0.15 mm Drill1mm Boring Bar(0.08mm depth of cut) 14.
Measures vibration in 3 axes Measures temperature Can be used to
monitor Tools Bearings Machine crashes Temperature variations The
sensor can be monitored in thebackground and can retain excessive
impactdata for later analysis Small size (40mm x 16mm x 6mm) 15.
Each SpindleMotor/drivecombination PCPower SensorETHERNETPower
SensorI/OETHERNETTMAC-MP ETHERNETFanuc control
ProcessorSystemMicro/SensorsUSBAccelerometers Power SensorUSB 16.
Many coolant flow/pressure sensors can be used. The user sets the
minimum flow/pressure allowedper tool If the coolant flow/pressure
drops below thislevel, an alarm is generated All coolant
flow/pressure is also graphed and canbe reviewed with TMAC Viewer A
variety of flow/pressure transducers are availabledepending on the
maximum pressure andminimum flow rate to be monitored 17. Each TMAC
process has the ability to monitor power, strain orvibration for
any tool. Each sensor works on the same principle thatas the tool
wears the signal will increase Power MonitorVibration Monitor Micro
ToolFor each type of monitoring there is a wear limit(yellow) and
anextreme limit(red) that can be used. Also, an undercut
limit(blue)can be used to determine if the tool is missing 18. By
measuring the actual cutting load in real-time, the system
canadjust the feedrate to maintain a constant load throughout the
cut This allows the tool to cut at its optimum load and also reduce
aircutting Any variation in the cutting environment such as
material, toolingand even coolant delivery will be compensated for
Feedrate adjustments are made constantly and in small increments(1%
of the programmed feedrate) to allow a smooth adjustment 19.
Historical data can beviewed and analyzedData can be exported
toprograms like Excel formore advanced analysisAll data is data and
timestamped and shows anyalarms that occurred 20. TMAC MP is a
complete solution for monitoringboth the tools and the machine with
the abilityto adapt to changing cutting conditionsYour
profitability will be increased by: Increased machine utilization
by decreasingor eliminating broken tools. Higher machine efficiency
with adaptivecontrol Less scrap and lower overall tooling costs
Attainable unattended lights outproduction
