I. OMAT control system function description Although the cutting conditions change with the change of the cutting process, each step of the CNC machine tool is carried out according to the constant feed rate programmed by the program. However, if the OMAT adaptive controller (OptiMil-XL, the OptiTurn-XL, the OptiDrill-XL, the OptiGrand-XL) is directly connected to the CNC machine, It is possible to monitor the actual cutting conditions and automatically adjust the feed rate for each step to the most appropriate value. The OMAT adaptive controller ensures that the user is no longer limited by the programmed feed rate. This will shorten the machining cycle while protecting the tool from damage.
1. Tool damage and spindle drive automatic protection Under the control of OMAT adaptive control system, the machining parameters will automatically adapt to tool load and cutting conditions in real time. For example, in the case of overload, that is, the impact of a tool or workpiece in an emergency, the diameter of the workpiece blank increases too much, etc., the feed rate is automatically reduced to the maximum allowable value determined by the expert system inside the system. After the extremes have passed, the system increases the feed rate to the maximum allowable value.
When using OptiMonitor-XL, each step of the tool "use only monitoring" instead of "feed control", when there are two different levels of overload, the LED will report the following two different degrees with different illuminating colors. Overload: (1) Overload degree overload? When the overload reaches the maximum allowable degree of the tool (using the tool, spindle and tool overload that has been damaged by grinding), the alarm light of the system glows red and the machine stops moving. (2) Alarm level overload? When the overload reaches this level, the alarm light of the system will be yellow, and the machine can be selectively stopped. The OptiDrill-XL is equipped with special algorithms to prevent damage to the tool, including in extreme situations, such as in "transverse perforation" cutting.
The OptiTurn-XL senses when the cutting load reaches the maximum allowable value of the spindle turning device. Once the OptiTurn-XL senses this state, it responds by reducing the feed until the cutting load falls within an acceptable range. As long as the cutting conditions permit, the OptiTurn-XL increases the feed to the level corresponding to the maximum allowable cutting load. OptiMil-XL, OptiDrill-XL and OptiMonitor-XL detect operating conditions to determine when the maximum allowable load on the spindle is reached, and if necessary, stop the machine to prevent spindle and machine damage, and an alarm is issued to alert the operator.
2. Tool wear automatic feed adjustment Considering the wear of the tool, the load of the spindle will gradually increase. The OMAT adaptive controller can ensure the proper feed according to the wear amount of the tool. With the OMAT adaptive control system, CNC programmers do not need to be overly conservative when programming feeds. The feed can be set as in the case of using a new sharp tool. The adaptive controller compensates for tool wear throughout the cutting process during the cutting process. This means that the machining cycle is always minimal and not at the expense of the life of the tool.
(1) Tool wear monitoring function In production, the OAMT control system can learn to monitor tool wear by machining the first workpiece. In subsequent machining, the OMAT control system continues to monitor the condition of the tool and display it as a percentage of the maximum wear of the tool. When necessary, the operator can be reminded at the end of the program to change the tool for maximum cutting efficiency. If a drilling process has a predetermined number of hole machining, the OptiDrill-XL can also alert the operator to change the tool if the tool is excessively worn at the end of the process. If the tool wear reaches 100%, the OMAT control system can activate a dedicated output that can be connected to peripherals such as off-the-shelf spare tool magazines.
(2) Tool damage detection function If the user enables this function, OMAT's adaptive controller and OptiMonitor-XL can learn to detect tool damage when cutting the first workpiece. In the event of tool damage during cutting of subsequent workpieces, the OptiMil-XL, OptiDrill-XL and OptiMonitor-XL respond immediately, issuing a tool damage alarm, stopping the machine's movement and switching on the dedicated output. This output can be connected to peripherals, such as off-the-shelf spare tool magazines. The OptiTurn-XL only starts the damage response of the tool at the end of the current pass.
(3) Tool overload detection function During the cutting process, for any particular tool, when the actual tool load reaches the “alarm†overload limit, the adaptive controller and OptiMonitor-XL respond and illuminate the overload LED to sound an alarm. In order to take remedial measures, such as changing the tool in time, modifying the feed rate and spindle speed. When using the OptiMonitor-XL, no action is required when the load reaches the "overload alarm" level, and the machine is stopped in response to an overload when the actual tool load reaches the "overload stop" level.
(4) Tool life extension function In the case of extreme overload, the OMAT adaptive controller reduces the feed rate. This reduces tool wear in many situations and extends tool life.
(5) Tool performance statistics function While controlling and monitoring by the OMAT adaptive controller and OptiMonitor-XL, all the performance data of the tools used in the cutting process can be counted. These data include the cutting time, the wear of the tool, and the minimum feed override measured during the cutting of the pass during the adaptive controller's participation and non-involvement control. The current cutting data is only displayed at the end of the pass, but all accumulated tool data can be displayed at any time. If you use OMAT-Pro software, you can get more detailed statistics.
(6) Coolant monitoring function When using the OMAT optimization system, it can be set to continuously monitor the flow rate of the coolant. The user can set a flow threshold as desired to maintain this flow throughout the cutting process. If the flow interruption time reaches the length of time programmed by the user, the system will stop the movement of the machine.
Second, the OMAT control system mode setting OMAT optimization system allows the user to select a control function for each step to optimize system work. Fully optimized mode: real-time feed rate adjustment (increased efficiency and dynamic tool protection in roughing and semi-finishing); monitoring mode: (tool protection and process monitoring during finishing); event recording mode: only Data recording is performed to subsequently download the recorded data to a PC on which OMAT-Pro is installed.
Once a certain mode of operation is selected, only the parameters related to that mode of operation are displayed on the menu. For each step of cutting, the material of the tool and workpiece is selected from the tool magazine and material library of the system, and the cutting parameters also need to be input. Another method is to use the OMAT-Pro software to set the process on the PC, and then automatically download the process setting data from the PC. Only the pass steps that you want to monitor, adaptive feed control or event logging need to be set in the process. The system can store a large amount of cutting pass data (see technical specifications) for subsequent use in the same machining. When setting up the process, you do not need to make any modifications to the existing NC program except for adding a simple program string every time you change the tool in the program. The purpose of adding a string is to tell the system when to start or stop. In addition, each start command gives the system a notification to tell the machine which step to take. If OMAT-Pro is installed, these CNC strings can be automatically inserted into the NC program via OMAT-Pro.
Once setup is complete, the system naturally enters the automatic mode and automatically controls those set cutting passes throughout the cutting process. The OMAT adaptive controller keeps the tool's load at its maximum allowable level by identifying the tool and material selected during the process setup phase. This means that the controller is controlled in accordance with a special algorithm adapted to each step of the cutting pass, and this algorithm continuously calculates the appropriate feed rate based on the measured load value. Finally, the machine applies this feed rate to the machining in real time.
Third, the application of OMAT excellent control system OMAT excellent control system is used to monitor the spindle power during the processing and automatically adjust the feed rate. More specific applications are listed.
OMAT Control System Option Function 1.OMAT-Pro OMAT-Pro is a Windows-based application software that can be used on a PC or on a PC network connected to the OMAT control system. It is also a management tool for field managers that can effectively monitor and control the production of machine tools. As a machine shop production management system, OMAT-Pro integrates functions such as event logging, production performance monitoring and data statistics reporting. The production, machine and tool statistics that OMAT-Pro can report and display include: (1) machine tool downtime; (2) machine and tool utilization; (3) machine state (spindle rotation state, overload condition, Whether it is in the cutting state, etc.); (4) the number of times of machining; (5) the number of workpieces processed; (6) the tool, machine tool, operator and shift change.
OMAT-Pro graphically shows in real time how OptiMill-XL, OptiTurn-XL, OptiDrill-XL, OptiGrand-XL and OptiMonitor-XL control the cutting process of CNC machines. These data can be graphically displayed in real time on the screen of the PC, and the processing can also summarize the cutting process. OMAT-Pro can process the event-related data recorded on the PC as needed, and then display the data as statistical data immediately or later. These reports include comprehensive information on production workpieces, machine tool conditions and tool utilization. With OMAT-Pro, users can set up their OMAT control system on PCs that are far from the machine, and can generate a database of cutting operations on a PC. In addition, OMAT-Pro can help set process parameters, build tool magazines, manage working parameter libraries, edit NC programs, and exchange data with OMAT control systems via communication connections. With OMAT-Pro, changing the different processes does not necessarily require manual input of data into the OMAT control system, which is especially useful for repetitive machining. Regardless of the number of machines and the number of tools, OMAT-Pro is able to store the corresponding data and provide effective support even when it comes to the widest range of machining operations.
2. Data Logger and External Alarm This optional system is a highly integrated and portable temporary storage device that stores process and tool data. Data loggers can be used to store data, whether in the shop floor environment or in an office environment, or to transfer data between an adaptive controller and a PC with OMAT-Pro installed.
If there is no RS232 connection between the OMAT-Pro user's machine and the PC, a data logger is recommended. In addition to the standard LED warning lights, the OMAT adaptive controller can be equipped with an external alarm. If there are various extreme situations, the system causes the machine to stop, and then the operator of the machine can be alerted. The OMAT adaptive control technology is used to optimize the metal cutting CNC machining process and improve the machining efficiency. Contour milling saves about 38%; milling slots save about 34%; 3D milling saves about 37%; drilling saves about 28%.
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