WCA September 2022

Technology News

Solving tomorrow’s problems today, to engineer a better future

The range of MHM products from Decade Monitoring Solutions enables targeted process improvements to optimise return of investment from manufacturing lines through reduced downtime and energy consumption, and enhanced product quality. Machine tool monitoring (MTM) utilises integrated systems and devices that monitor the condition of tooling, gathering critical data that can be used to determine the health and remaining life of a tool. There are numerous types of press tools, such as simple, compound, progressive, combination, forming and hybrid, and each has a different set of parameters to be monitored, including tool load, temperature, quality of oil and operating sequence. Capturing accurate data from the operation of the tool and understanding the change over time allows tool life to be predicted, and potential tool failure to be identified early. A tool monitoring system (TMS) can be beneficial for industries that use machinery for manufacturing and in aiding their processes, especially when used in conjunction with MHM systems. Downtime and potentially damaging conditions are made easier to predict, with indications of early failure detected by monitoring critical parameters of the machinery. the in-line surface inspection of most extruded products, including cables, tubes, hoses and other goods made of plastic, rubber and other materials. With the consistent implementation of machine vision and machine learning, the SIMAC meets market demands for a compact, industrial-proof system. The system provides continuous in-line surface inspection, and works with all surfaces and colours. Ultra-bright LED panels allow the detection of defects on dark surfaces. Four cameras ensure 100 per cent coverage, even for small products, using overlapping zones. The measuring field is 40 or 70mm, with a diameter range of 2 to 63mm, and the maximum scan rate is 140,000 scans/s. Advanced algorithms search the

Machine health monitoring (MHM), also referred to as condition monitoring, provides real-time metrics to assess the operating state and general condition of a machine. Advanced data analysis of machine operating conditions such as temper- ature, speed, position, vibration and load curves allows for a qualitative assessment of the machine’s health. Manufacturers know the details of their products and the processes to be controlled. However, it is more difficult to understand manufacturing variability without insight into detailed operating conditions of the machine. Each machine has a “signature” that changes as the machine wears, and understanding the changes helps understand the health of the machine. The advantages of investing in MHM devices and software include asset protection, product quality, reduced waste and improved overall effective efficiency (OEE). Unexpected machinery downtime can be reduced or prevented. MHM can further optimise operating conditions for greater efficiency, with operators and maintenance teams able to employ pre-emptive targeted maintenance. Metrics captured from critical operating parameters can be analysed to allow better allocation of budgets and capital investment.

The control screen of Decade’s 170 Series press automation system

Monitoring the health of tools and ensuring they are maintained at optimum levels can improve the performance of tooling. A TMS helps to give visibility to the condition of tooling and target pre-emptive maintenance, which in turn improves the life of the tool. Decade Monitoring Solutions works with a range of industries, creating off-the shelf and customisable solutions for all types of presses, including both manual and automatic machinery. The company has more than 40 years’ experience of designing tailored solutions using an in house engineering team. The company states that all industries working with machinery can benefit from machine health monitoring, including aerospace, agriculture, automotive, de fence, electronics, heavy manufacturing and energy and power generation. Decade Monitoring Solutions Ltd www.decade.co.uk image for defects based on pre-trained examples, and data is recorded for later analysis and defect detector training. Defects are stored in a database. A side opening in the housing allows quick and easy introduction into production lines, and the compact design makes maintenance easier. As a major manufacturer of in-line measuring and control systems, Zumbach is committed to extensive research and development of the technology. The company states that its priority is customer relationships through local presence combined with quality products, services, personal consultations and support. Zumbach Electronic AG www.zumbach.com

In-line surface inspection system The SIMAC® 40/70 replaces its

predecessor in the Zumbach range of surface inspection systems. Using the latest image processing technology, the SIMAC meets current requirements for

Zumbach’s SIMAC surface inspection system

29

www.read-wca.com

September 2022