Ernst Kulli

GIORNATA DI STUDIO SU UTILIZZO DI SENSORI PER IL MONITORAGGIO DI

MANDRINI PER FRESATURA E RETTIFICA

Usage of sensors in the spindles forhigh performance cutting and precision machining

State of art and new technology

Ernst Kulli

Contents

1. Introduction

2. Spindle integrated sensor

3. Case study of high performance cutting

a. SmartVision

b. SmartDrive

4. Case study of precision machining

a. DMD

b. Shaft cooling

Ernst Kulli

Fischer AG Precison Spindles

- Founded 1939- In the second generation of family ownership

- Location Herzogenbuchsee- 170 Employees

Fischer Precise Group: 3 Brands 7 Locations

Ernst Kulli

Rotation

The name stands for

PRECISE, FAST and POWERFUL rotation

~ 4000 BC.

Ernst Kulli

Quo vadis?

SpeedPrecision Power / Torque

High Power

High Torque

Precision parts

Surfaces

Grinding

Small tools

Ernst Kulli

Bearing

Air bearingBall bearing Hydrostatic Magnet

StaticCompressed air is introducedDynamicAir cushion is built up by the movement itself

Angular contact ball bearingsCylinder roller bearingsand others

StaticLiquid is introduced underpressureDynamicPressure in the fluid buildsup by the pumping action of the two part surface

Contact freeBearing forces isgenerated by controlledelectromagnets

Ernst Kulli

Contents

1. Introduction

2. Spindle integrated sensors

3. Case study of high performance cutting

a. SmartVision

b. SmartDrive

4. Case study of precision machining

a. DMD

b. Shaft cooling

Ernst Kulli

SensorsMotor temperature

Speed

Axial position of interface

Current

Bearing temperature

Vibration level

Number of tool changes

Shaft angle positionForce flow of bearings

Structureacoustic noise

Leckage

Flow rate

Voltage

Ernst Kulli

Sensors

Visualize the condition of the spindle

Records the measured datas

Analysis exceeded warning levels

Registered alarms

Allows to create reports

Safe operation of spindle

Optimization of the machining process

Smart Vision

Ernst Kulli

0

2

4

6

8

1 0

1 2

1 4

2 0 0 0 0 2 1 0 0 0 2 2 0 0 0 2 3 0 0 0 2 4 0 0 0 2 5 0 0 0 2 6 0 0 0 2 7 0 0 0 2 8 0 0 0 2 9 0 0 0 3 0 0 0 0D re h z a h l [1 /m in ]

Schn

itttie

fe, a

p [m

m]

s ta b ile r S ch n itt R a tte rn E xp e rim e n te lle S ta b ilit ts k a rte

F r s e r N r. 7 9 6 8 5 7 1 , D 1 6 lg e s = 1 6 6 ,5 m m , la = 7 5 ,5 m m2 S ch n e id e n , V o llh a rtm e ta llV o lln u t, fz = 0 ,1 8 m m

0

2

4

6

8

1 0

1 2

1 4

2 3 0 0 0 2 4 0 0 0 2 5 0 0 0 2 6 0 0 0 2 7 0 0 0 2 8 0 0 0 2 9 0 0 0 3 0 0 0 0D re h z a h l [1 /m in ]

Schn

itttie

fe a p

[m

m]

F r se r 8 6 2 0 4 5 2 , D 1 6 lge s = 1 3 9 m m , la = 4 8 m m 2 S c h n e id e n , V o llh a rtm e ta ll V o lln u t, fz = 0 ,1 8 m m

s ta b ile r S c h n itt R a tte rn E xp e r im e n te lle S ta b ilit ts k a rte

Itotal = 139 mm

Ia = 48 mm

Itotal = 166.5 mm

Ia = 75.5 mm

Sensors

Ernst Kulli

Forc

e [a.

u.]

Time [a.u.]

Machining forces

5 revolutions

Sensors

Ernst Kulli

SmartVision ReportCustomer send his recorded SmartVision Data backfor analysis by Fischer Engineers.

You will get back an analysis of: Productivity of the machine

Spindle power and torque utilization

Spindle speed utilization

Observations by experienced spindle experts

Recommendations for improving spindle reliability

Ernst Kulli

Contents

1. Introduction

2. Spindle integrated sensor

3. Case study of high performance cutting

a. SmartVision

b. SmartDrive

4. Case study of precision machining

a. DMD

b. Shaft cooling

Ernst Kulli

High Power Milling

Example: Aeronautical structure partsWith spindle power of over 150 kW material removal rate of > 15 l/min are achievable.

Fischer converterfor high power

MFW-2320/30100 kW, 48 Nm S1

MFW-2715/20150 kW, 96 Nm S1

Ernst Kulli

High Torque Milling

Example: Structure parts for energygenerationHigh torque for roughing and high speed forfinishing are necessary to mill difficultmachinable materials with long tools

MFW-2702/08445 Nm, 93 kW S1

MFW-2801/16198 Nm, 28 kW S1

Ernst Kulli

SmartDriveStrong

Current up to 300 Aeff,sufficient for spindle power of 200 kW

Fast Special modulation method up to

20 kHz: high torque and high speed in combination

Current control loop cycle time 2 s Sensor Signal processing, including

recording in 0.2 ms cycle time[PLC Function]

Intelligent Design One connection for all Spindle Sensors Spindle Electronic on Board PC integrated for monitoring of spindle sensors

Ernst Kulli

SmartDrive Process AnalysisView through the Spindle

Process Analysis of Speed Torque Power Vibration at the Cutting Edge

Integrated Oscilloscope Highest Resolution Detailed Information

Communication to CNC Control Exceeding of limit values Quick Signal variation during processing Envelope monitoring or Teach-in Cycle

to optimise the Cutting Process

Ernst Kulli

Contents

1. Introduction

2. Spindle integrated sensors

3. Case study of high performance cutting

a. SmartVision

b. SmartDrive

4. Case study of precison milling

a. DMD

b. Shaft cooling nano

Ernst Kulli

Thermal constant process condition

Shaft cooling

Benefits1. Shortening the time untilsaturation of temperature

Time reduction -80%

Time

Spin

dle

tem

pera

ture

Without shaft cooling

Shaft cooling

Ernst Kulli

Thermal constant process condition

Shaft cooling

Benefits2. Reduction of shaft elongation

Zeit

Without shaft cooling

Shaft cooling

Dilatation -70%

Ernst Kulli

Displacement Measuring Device

Compensation of thermal and mechanical spindle growth

Ernst Kulli

Thank you for your attention

Ernst Kulli

Senior Engineer

Fischer AG Przisionsspindeln

3360 Herzogenbuchsee

ernst.kulli@fischerprecise.ch

www.fischerprecise.ch