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NC AND CNC MACHINERY DIAGNOSTICS

Machine tools condition monitoring is main prerequisite for maintainig production quality as well as necessary requirement in quality control systems according to ISO 9001 standards. Observe machinery preventive geometry according to production wasters is obsolete. Current tendency is to foresee - predict machinery condition and ensure production quality accordingly. Following this it is possible to ensure satisfactory production even on machinery with worse characteristics.

This provides ESOS Ostrava company by decreasing machinery service costs and at the same time maintain high production quality by means of NC and CNC machinery diagnostics. This is applied throughout our customer base especially companies working in machinery industry.

Registry is being compiled from performed measurements which gives us continual view of machinery development. Which particular machine tool is capable of fulfiling requirements for manufacturing accuracy can be assessed with use of this registry. With this clasification and its periodical repeating is possible to decrease scrap costs comming from allocating product to particular machine. By observing development trend of manufacture accuracy is possible to schedule machinery maintenance/repair before major malfunction occurs. This will significantly decrease costs caused by machinery breakdowns.

Customer gets overview of his machine pool accuracy including machinery accuracy protocols according to ISO 9001 standards.

Diagnostics according to ISO 230 – 1

Geometry measurement (Schlesinger)

Machine tool basic geometry measurements (perpendicularity, straightness, flatness, circumvolution, alignment, and axis identity) according to ISO 230-1.

Measuring is always carried out on unloaded machine. Measuring period depend on machine type.

Protocol is compiled from actual measurement and contains:

Table of measured data
Machine`s condition evaluation
Recommendations on found faults

Supplemental measurement (machine-table flatness, machine bed lead etc.)

Flatness and true position of machine-table measurement, machine bed lead, by preparative, dial gauge, electronic water level MINILEVEL.

Measuring is always carried out on unloaded machine. Measuring period depend on machine type.

Protocol is compiled from actual measurement and contains:

Measurement schematics
Graphic representation of actual shape or position of machine tool
Machine`s condition evaluation

Machine tools set-up (establishing of equilibrium)

Machine tools set-up (establishing of equilibrium) is important especially for lathes where it has direct connection with machine tool geometry, headstock spindle and carriage axis alignment.

Machine tool set-up is laways followed by control measurement according to ISO 230-1.

Protocol is compiled from actual measurement and contains:

Measurement schematics
Table of measured data
Machine`s condition evaluation
Recommendations on found faults

Diagnostics according to ISO 230 – 4

Geometry measurement and measurement of drive adjustment by circularity analysis.

Geometrical errors can be catched up with this measurement (perpendicularity, straightness, backlash, cross clearance…), electronical errors (drive unit delay, trailing error, gauge linear error).

Measuring is always carried out on unloaded machine. Measuring period depend on machine type and number of measured planes.

Protocol is compiled from actual measurement and contains:

Circularity analysis according to ISO 230-4
Table of measured data
Table and diagnosis of measured errors
Machine`s condition evaluation
Recommendations on found faults - development trend of measured errors is
compiled at periodical measurement

Correction into selected control systems

Up to certain levels of mechanical errors (based on dynamical measurement) is possible to input corrections into control system to achieve improvement of machine tool accuracy.

This includes constrol systems: Heidenhain TNC 307 to 530i, MEFI, Sinumerik 810D, 840D, GE FANUC series 0,5,6,16,18,20,21,16i,18i,20i,21i.

Corrections input into control system follows machine tool control dynamical measurement according to ISO230-4. Protocol is compiled from this measurement (see geometry measurement).

Supplementary static measurement of repeatability

This measurement is suitable for production in large series when repeatability of tool or workpiece impositioning into position is emphasised.

Measuring is always carried out on unloaded machine. Measuring period depend on machine type and number of measured planes.

Protocol is compiled from actual measurement and contains:

Graphical representation of tool impositionig into position
Table of measured static repeatability data.
Table of measured maximal repeatability data
Machine`s condition evaluation

Diagnostics according to ISO 230 – 2

Laser (interferometric) geometric measurement

This is so far the most accurate machinery diagnostics.

Machine geometry can be catched up with this measurement (perpendicularity, straightness, flatness, cross clearance, backlash, gauge adjustment).

Measuring is always carried out on unloaded machine. Measuring period depend on machine type and number of measured planes.

Protocol is compiled from actual measurement and contains:

Graphical representation of error behavior along measured axis length
Table of measured data
Machine`s condition evaluation
Recommendations on found faults

Measurement of gauge adjustment including corrections

This measurement can adjust gauge (non-linear) which means that measured axis is divided into given number of smaller positions (2 000 mm min. for 5 measured positions) which are compensated according to actual measured error.

Measuring is always carried out on unloaded machine. Measuring period depends on number and length of measured axis.

Machine is measured before corrections first. Corrections are inputed and control measurement is carried out.

Protocol is compiled from actual measurement and contains:

Graphical representation of error behavior before corrections
Table of measured data before corrections
Graphical representation of error behavior after corrections
Table of measured data after corrections

Vibrodiagnostics

periodical machinery and tools measurement, bearing condition monitoring and detection of dynamic conditions like unbalance, abaxiality etc.
non-periodical measurement of problematic machinery
implementation of vibrodiagnostics into maintenance system

Tribodiagnostics

basic analysis of oil and lubricant samples
- for haulage contractors and construction machinery
- for processing machinery and tools

For processing machinery

For haulage contractors