预防批量不良，降低产品缺陷风险
通过设置刀具的磨损极限，实时监测刀具的磨损状态，当刀具的磨损到达极限时，及时给出换刀信号，避免因为刀具提前失效而导致的零件批量性缺陷。
By setting an upper side boundary for signals of tool wear and
monitoring tool status, the system will release a signal to tell customers the
best timing to change tools when tools have reached their limits,which can
avoid massive defects in volume production caused by unexpected faster tool
wear.
为刀具性能评估提供决策依据
通过刀具磨损监控系统采集到的实时加工数据进行对比分析，可以评价刀具的性能。
The
system can compare historical tool wear data to provide evidences for
decision-making of tool performance evaluations.
消空程／防碰撞系统
Gap Eliminator
(GE)
消空程／防碰撞是一套能够缩短磨削过程中的空程时间，并避免砂轮和工件发生碰撞的智能控制系统。
适用范围：各类磨削应用
Gap Eliminator is a package of intelligent control system that
shorten free stroke time in grinding processes and avoid severe impact or
collisions between grinding wheel and workpieces at the same time.
Applicable fields:all kinds of grinding applications
效率提升
原实际加工时间为38s，使用消空程／防碰撞系统后节拍降低到32s，节省6s，效率提升15％左右。
Original
cycle time was 38 sec.When GE systen was installed,cycletime was reduoedto 32
seo, so the efficiency was improved about 15%
防碰撞
原来无碰撞保护，导致主轴撞坏设备维修，使用防碰撞系统后，软件自动识别反馈，发出控制信号给机床，机床复位并发出报警信号。
After
GE system was installed,software automatically recognized prercoll ision
signals,and then gave comundsto machine.Grinding machine fed back and released
alarm at the end.
提升磨削效率
在磨削过程中，消空程／防碰撞系统通过砂轮接触工件所产生的信号变化，来有效提示机床切换移动速度，降低空程占用的时间，使加工效率大幅提升。
In grinding processes, GE system controls machine' sfeeding speed
in accordance with signals from the contact between wheel and workpieces in
order to reduce the time of free stroke and raise the efficiency up.
有效控制因来料尺寸异常所造成的碰撞及品质风险
由于来料异常，会导致异常零件在快进阶段与砂轮发生剧烈碰撞，对砂轮、主轴和夹具都会产生损坏，消空程／防碰撞系统可以对此类情况进行有效的监控，当异常发生时，及时发出报警给机床进行停机，降低因碰撞带来的各种损伤。
It
is possible for grinding wheel to have severe collision with abnormal parts
when approaching,due to uncertainty of in-coming parts,which could destroy
grinding wheel,fixture even spindle.Therefore, GE is invented to monitor such
situation.When collision is going to happen,GE releases alarm immediately to
stop machines and to prevent collision and following damage.
自适应加工系统（功率版）
Adaptive Machining-Power(AM-P)
自适应加工（功率版）是一套能够实时测量主轴负载，同时调节进给倍率以提高加工效率的智能控制系统。
适用范围：单件／批量加工、半精加工、粗加工（攻丝、恒线速车削除外）
Adaptive
Machining -Power(AM-P) is a packege of intelligent control system that measure
spindle load and adjust feed rate simultaneously to achieve higher machining
efficiency.Applicable fields:Single/mass production,semi-finishing,roughing
(except tapping and turning with constant linear speed)
效率提升
原实际加工段平均时间为91秒，使用“自适应加工系统”后节拍降低到77秒，效率提升15.4％。
Original
cycle time was 91 sec. After AM-P was appl ied on the machine. the cycle time
was reduced to 77 sec,whose efficiency was raised by 15.4
刀具过载保护
由于来料异常，导致切削量异常增加，使得刀具负载超过设定上限，系统及时输出报警至机床，加工暂停。
Because of
unusual stock removed,power signal showed that spindle load wes out of limit at the begiming Thus,AMH-P control led the
machine to stop and release alarm imediately.
提升加工效率
数控机床在加工时，会根据程序中给定的进给速度进行切削。切削过程中，加工外部条件是会发生变化的，而设备却不能够对随时变化的加工条件做出相应的调整。自适应加工（功率版）通过实时测量主轴功率，利用自适应算法最快地计算出合理的进给速度，并及时调整进给倍率，负载小的工况，增大进给速度：负载大的工况，减小进给速度，达到恒功率切削的目的。
When machine is working, it cuts under certain feed rate according
to program.During cutting process,cutting condition is changing time to time,
but machine can not feedback and adjust properly based on that.Therefore,based
on power signal and our adaptive algorithm,AM-P is designed to calculate proper
feed and adjust feed rate in the shortest time. In order to reach a
constant-power machining, AM-P will increase feed rate if power is lower than
its standard and vice versa.
刀具过载保护
加工负载过大会导致加工过程中出现“闷刀”现象，自适应加工（功率版）对每把刀具自动计算负载上限，当功率超过上限时，输出报警，达到保护刀具和机床的目的。
Cutting
tools could be jammed when the when the cutting force is over load. To avoid
this situation, AM-P automatically calculates an upper limit of power for each
cutting tool.When tools are overloaded, it will output alarm to protect tools
and stop the machine.
机床热误差补偿系统
Machine
Tool Thermal Error Compensation(MTEC)
机床热误差补偿系统基于机床各轴温度变化，建立对应的热误差补偿模型，能根据其对各轴进行实时补偿，以保证机床的高加工精度和批量稳定性。
适用范围：各类机床
The MTEC is used to build up the thermal error compensation model
based on the temperature of each machine tool axis,and can compensate the
machining accuracy and product stability.
Application fields:All types of machine tools
主轴热补偿
补偿前后，主轴的最大热误差减少约71％，补偿效果良好。
After MTEC application,the
spindle thermal
error is compensated by 71% with very good effect.
进给轴热补偿
补偿前后，X轴进给轴的最大热误差减少约80％，补偿效果良好。
After MTEC application the spindle thermal,error is compensated by
80% with very good effect.
提高加工精度和批量稳定性
工件加工过程中，机床各轴产生的热误差可能会导致工件尺寸波动大，甚至超差产生不良品。机床热误差补偿系统通过实时补偿各轴热误差，提高了加工精度和批量稳定性。
When machining a part,thermal error can cause large fluctuation of
dimension,and even lead to defective products. MTEC is able to improve
machining precision and batch stability by compensating the thermal error in
real time.
降低热机时间
正常加工前，机床通常需要较长时间来热机至热稳态，才能保证产品加工质量。机床热误差补偿系统避免了长时间的热机过程，从而达到降低时间成本和能耗的效果。
Before
machining a part,the machine tool usually needs long time to warm up to reach a
thermal equilibrium state, so that the product quality can be ensured.MTEC can
help to avoid this long period of warm-up process and decrease time cost and
energy consumption.
降低机床使用环境要求
环境温度的变化可能也会导致热误差的产生，在温差大的地方尤其明显，为了保证加工精度，甚至可能需要使用恒温车间。使用机床热误差补偿系统大大降低了环境温度的影响，不需要恒温车间也能达到较高的加工精度，从而达到降低基建成本的效果。
Environment
temperature changes can also lead to thermal error,especially in those places
with large temperature difference.In order to ensured the machining
precision,constant temperature workshops may even be needed.Using MTEC system
can reduce influence of environment temperature a lot. The machine tool users
can keep high precision without working in a constant temperature workshop.so
the construction cost can be reduced as result.
碰撞缓冲系统
Collision Buffer (CB)
当主轴／刀柄／刀具和工件／夹具发生突然的碰撞时，碰撞缓冲系统会自动感知碰撞信号，快速地发出报警信号给机床做急停，避免主轴因意外碰撞而损坏。适用范围：所有类型机床、机械手
When spindle/tool shank/tool body collides with workpiece/fixture.
CB system detects the collision signals automatically. and releases alarm to
stop machines rapidly,avoiding the catastrophic damage on spindle. Application fields:machine tool and robot
响应速度快
当发生碰撞时，CB系统能在3毫秒内快速响应，输出信号给机床停机
When the
collision was happened,the CB system will respond quickly within 3 milliseconds
and output a signal to stop the machine.
安全性高
撞机发生后，CB系统最大可能的保护主轴不受伤害
After the
collision,the CB system can protect the spindle from damage as safe as possible.
撞机前后--主轴静态精度测量结果
Before and after--Comparison
of spindle static precision measurement results
撞机前后--主轴动态精度测量结果
Before and after--Comparison
of spindle dynamic precision measurement results
预测性维护系统
Predictive Maintenance(PM)
预测性维护系统是监控设备关键或易故障部件老化故障的智能监控系统。该系统通过对设备热机或空转过程中的多源信号进行分析，提取设备部件的预维特征，实现长期监控设备老化故障趋势并预警的功能。
适用范围：机床主轴、进给轴传动部件。
Predictive
maintenance(PM) is an intelligent system that monitors important components and
those with short mean time between failure.
This
product is able to extract PM features of components from multiple signals
during the heating-up or idle processes to monitor agingtendency of those
components and to warn customers when features are beyond their thresholds.
Applicable fields:Transmission mechanism of spindle and feeding.
系统架构
System Architecture
硬件包含：传感器及采集板卡，边缘计算终端
软件包含：底层预维软件，上位预维查看软件
Hardware:Sensors,Data
Acquisition boards and IPSoftware:PM lower computation software & PM upper
monitoring software
系统操作简单，评价准确快捷
客户能自由决定检查周期，定期执行1～2分钟的程序就能得知设备健康状况。
Customers are free to decide evaluation period and to execute a
2-minite program under this period to know health
status of equipment.
适用于各种场景，同时扩展性高
除了适合于标准设备的主轴和进给轴，产品可以根据定制需求拓展至其他设备部件。
Except for usual spindle and feeding axis,PM can be applied on
other components according to customers' demand.
案例展示：某知名品牌发动机缸体加工现场，共24台卧式加工中心；为其构建针对主轴和进给轴的预测性维护系统。
Case study:we deployed PM system on 24 horizontal machine centers
in a engine plant of a big brand.
价值呈现
Key value
价值1：在2020年6月发现编号为005号机床主轴预维特征值达到预警线，在2020年7月预维特征值达到报警线。设备维护部门于10月假期期间进行了主轴更换，预维特征值降至合理范围。同时换下来的主轴经过生产厂家确认，已无维修价值，需报废处理。
1st Value: In
June 2020, the vibration characters of spindle of #005 machine center achieved
early warning line on. After one month. it went beyond the warning line.With
double check from maintenance department,engineers replaced that spindle in
October.After that,the vibration characters returned to normal
value.Finally.OEM confirmed that the ball bearing of that spindle were severe
wear and there was no need to repair.
价值2：在对比排查24台设备进给轴预维特征值后，发现编号第8、12、16、22号设备的预维特征数据同比较高，在设备维护部门定期保养后发现进给轴出现了不同状况的故障。
2nd value:with the comparison of vibration characters of feeding
axis among 24 centers, customer found that #8,12.16 and 22 centers had obvious
higher value.After regular maintenance,these 4 centers had visible wear and
rust on ball screw.
24台设备横向对比
Comparison
of 24 machine centers
对应4个异常数据的锈蚀和磨损检查结果
Maintenance results of 4 abnormal
data