Manufacturers constantly seek to revolutionize their machining setups in the quest to achieve greater productivity and profitability. Many of them have traditionally taken to piecemeal upgrading individual aspects such as tooling, staffing, or maintenance. These advances resolve known challenges, viz. optimizing the machining process by reducing cycle times, ensuring longer tool life, or better managing manufacturing resources.
However, digitalization has brought about more holistic ways of improving manufacturing productivity, often identifying opportunities that human workers may not recognize. One such innovation is adaptive control and monitoring (ACM) software, which facilitates “intelligent” machining.
An ACM software is essentially a real-time solution for optimal machining that also analyzes the process to unlock further productivity gains. For instance, when applied to metal-cutting, it can help extend tool life by dynamically adjusting the machine’s feed rate based on conditions such as material hardness or tool condition. Such feed rate optimization also ensures that the tool’s full capacity is leveraged, with the software capable of compensating for human overcautiousness. Thus, it guarantees consistent part quality and maximizes the useful life of high-cost tooling.
Another equally important function of ACM software is real-time monitoring. In environments where tools operate under high loads for short durations, such as gun drilling or micro-machining, early detection of tool wear or impending breakage is essential. Reliable monitoring systems detect these anomalies without false positives, enabling smoother integration into automated workflows and reducing unscheduled downtime.
At the same time, the software also ensures through tool monitoring that the spindle does not get damaged due to tool breakage. While programming the correct dimensions usually takes care of such incidents, a real-time monitoring solution can sound the alarm and shut down the process.
Realizing the full potential of adaptive control and monitoring systems requires setting up the control algorithm to manage the entire machining process. In this configuration, the ACM software can record and analyze cutting or other process data and execute the necessary adjustments to achieve real-time increase in machine throughput.
Typically, installing ACM software does not require overhauling the existing machining setup, nor does it involve significant training of software operators or modifying the CNC programming. These factors result in a low total cost of ownership (TCO) which makes the performance enhancement even more attractive from a cost perspective.
One of the more trusted software suites is the Siemens Adaptive Control & Monitoring (ACM) suite. With over three decades of evolution, this ACM suite integrates seamlessly into existing machine configurations, supporting a wide range of operations including milling, grinding, turning, and more. It helps manufacturers achieve consistent performance with minimal operator intervention. Today, Siemens ACM suite is among the company’s portfolio of CNC Shopfloor Management software – digitalization solutions that testify to the widespread success and adoption of adaptive control technologies.
An illustration of the power of an ACM solution is the case of an Indian precision component manufacturer, Seinumero Nirman Pvt Ltd. Their pain point was spindle stoppages due to tool breakage for which the envisioned cure involved heightening the stability of their machining process and increasing the life of their cutting tools. Additionally, they aimed to reduce cycle time by at least 10% without changing their process.
By deploying real-time process monitoring and dynamic feed rate adjustment, they also enhanced transparency into machine status, enabling better production planning and cost control. As a result, they were able to optimize their cycle time by up to 15% during the roughing and semi-finishing phases. Consequently, they could produce an additional 21,600 components annually, which added INR 43.20 lakh to their yearly sales turnover.
Further, lowered power requirements also improved the sustainability of their machining setup. This example demonstrates how a tried-and-tested adaptive control and monitoring solution also helps manufacturers avoid the risks and costs associated with tweaking the NC programming and hiring or training operators for this purpose. Since the software suite is configured to work with the existing setup without requiring additional hardware, it is a custom solution that is certain to deliver the desired results. Investing in an ACM solution thus guarantees long-term dividends for manufacturers.
At Sharpedge Technologies, we offer state-of-the-art productivity solutions for a wide range of industries and applications in collaboration with world-leading innovative manufacturers. To learn more, call us at +91-9822194710 or email connect@sharpedgetech.co.in. You can also connect with us on LinkedIn.
