Machine vision and network work together to create machine tool unmanned operation editor's remark: "unmanned processing operation means that you don't have to stand in front of the machine tool to observe every processing action or listen to the sound of cutting tool processing parts all the time. The operator can leave the machine tool to do other things. However, in the working state of unmanned operation, you still need to check the working condition of the machine tool regularly."—— Corey Greenwald
the camera system installed on the machine tool is part of the whole system, which can help the staff of the processing workshop to complete more work in the workshop and save time. The manager of the company can monitor the working condition of the machine tool from a long distance. In order to respond quickly to accidents such as sudden tool wear or sudden tool fracture, some strategies have been studied and adopted without returning to the workshop to solve these problems
the establishment of hard milling solution is a bold creation of Mr. Corey Greenwald. The company is committed to guiding the reform of hard material processing. Hard material processing is considered to be a processing process that requires high professionalism of equipment and accuracy of technical knowledge. At that time, most of the processing workshops were not familiar with the milling of hard materials. Before Mr. Corey Greenwald adopted this technology to realize the flow operation of mold production, finish machining the details of quenched tool steel or producing complex medical components, no one had created such a processing workshop
this is a very bold adventure, because at the beginning of the establishment, Mr. Greenwald was neither a professional machining expert nor an experienced tool and mold maker; He is just an ordinary production engineer, fascinated by the many advantages of using hard milling technology. I used to manage the installation of hard milling forming punches and have rich experience in hard milling. After the installation of the new machine tool, the stamping production time was reduced from the original 30 days to 6 days. He clearly saw that if employees continue to work hard, there may be hope to achieve higher output. The potential prospect of hard milling encourages them to study this process comprehensively and seriously
the more knowledge Mr. Greenwald has learned about hard milling technology, the more he believes that the technology can create greater value. Therefore, hard milling solutions came into being. A good friend of Mr. Greenwald opened an EDM wire cutting workshop near him. With the help of this friend, Mr. Greenwald began to start a business in a rented plant in the northern suburb industrial park of Detroit, and purchased a V56 VMC vertical processing center from Makino company located in Mason City, Ohio
this is a groundbreaking work, and the advantages of hard milling technology still need to be improved Experimental report: (according to customer needs) one-step development. Different workshops adopt different technologies, but satisfactory results are not always achieved. However, Mr. Greenwald began to get rewards through his in-depth research on hard milling technology and his unremitting pursuit of the reliability and predictability of research results. He not only verified the experience learned from local machine tool distributors, tool suppliers and software resellers in practice, but also engaged in his own research
when Mr. Greenwald is sure of his 4 When the oil viscosity was too low and the company had solved the survival problem, he began to look for work that could further improve and optimize its technology. He experimented with different speeds and feed rates to push its process technology to a new level that had never been tested and verified. Because he has rich experience and profound insight, his ability and confidence in his workshop work are constantly increasing. Soon, he added a second machine tool, expanded the area of the workshop, and constantly updated the tool system and the programming software supporting hard milling technology
hard milling solutions is a very successful processing enterprise, and its business development is very stable. Mr. Greenwald seems to have obtained a secret about hard milling technology, which can be applied to the processing of injection mold, forging die and milling parts, and the hardness of its material can be as high as 65 HRC. In fact, Mr. Greenwald has become an advocate of hard milling technology. He firmly believes that hard milling technology should be widely used in mold processing workshops, medical parts factories and small production workshops. Not long after its establishment, hard milling solution added a third VMC vertical machining center of Makino company and planned to order a fourth machine tool when loading and unloading to arc heights of 0.7 times, 1.0 times and 1.3 times the rated load
greenwald gradually found that it takes a long time and arduous labor to master the hard milling technology. It takes a lot of energy to ensure the full load of the machine tool and give full play to the maximum efficiency of the tool. Trying to meet the wishes of every customer is almost his only work every day
another goal of Mr. Greenwald's hard milling method is to learn how to realize unmanned machining operations - the scientific and systematic methods necessary for hard milling. In fact, according to Mr. Greenwald, if hard milling technology wants to be more practical, more profitable and sustainable, it will be an inevitable development trend to adopt unmanned machining operations in hard milling technology. As he can see, making the machine run 24 hours is actually the key to achieving the highest productivity of the hard milling process
however, unmanned processing does not necessarily mean that the workshop is empty when the machine tool is running. This just means that the operator can leave the machine tool to do other things, such as repairing the tool, lowering the tool, and then selecting the connected COM port to directly program the online one-step work path, which can be carried out at the same time. Unmanned processing is only one part of the multi-function task of hard milling solutions
greenwald explained, "unmanned machining operation means that the operator can leave the machine tool to do other things without standing in front of the machine tool to observe every machining action or listening to the sound of cutting tools processing parts all the time. However, in the working state of unmanned operation, it is still necessary to regularly check the working condition of the machine tool." He recalled, "we debug the machine tool in advance so that it can work all night or all weekend, but we also have to arrange personnel to sacrifice the rest time of the night and check the processing of key parts from time to time. Even if we adopt the rotating duty system, it is also a burden for each person on duty."
greenwald first succeeded in hard material milling technology with the idea of combining inheritance and innovation. The system he created and implemented enables him to remotely monitor the processing and production of machine tools. In order to respond quickly to accidents such as sudden tool wear or sudden tool fracture, he also studied and adopted some strategies so that the staff did not need to return to the workshop to solve these problems
he installed video cameras on the machine tool and the processing area of the workshop, and made the home PC or notebook computer become the control board of the machine tool through the page based network software, so as to give full play to the automation function characteristics of its machine tool control system and the flexibility of its programming software, so as to facilitate the replacement of new tools needed and ensure the unmanned operation of the machine toolMr. Greenwald said, "the system enables the machine tool in the workshop to run for nearly 24 hours in only one working shift, and the effective working time of the machine tool is as high as 96%. More importantly, I and my employees can have more leisure time."
video camera system monitors unmanned operation
the first step in building an unmanned processing environment is to install a video camera and connect a digital video recorder (DVR) to the Internet. Because the hard milling method is based on the processing technology that has been proved by practice, regular inspection of the "unmanned" machine tool is enough to manage the occasional fracture of the tool caused by process changes or programming errors. However, it is also necessary to visit the workshop every few hours in the evening or on weekends. "The purpose of installing cameras is for them to undertake these daily unnecessary inspections," Mr. Greenwald said. "Obviously, this part of the work is very easy."
installation is very simple and direct. Mr. Greenwald hired a local supplier to install the commercial digital video cameras on the shelves into the sealing covers of three machine tools, and install another camera on the wall to monitor the working conditions of the machine tools in the whole workshop. The camera in the machine tool is first installed on the smaller mounting plate, and then fixed on the sheet metal part of the machine tool with bolts. The video transmission cable is led out from the top of the sealing cover of the machine tool, and then connected to the monitoring station of Mr. Greenwald's office through the ceiling of the workshop. The 15 V DC power line of each camera is connected to a transformer through a round hole on the sealing cover of the machine tool, and then it is inserted into the socket on the nearby wall. According to Mr. Greenwald, the installation of the camera system took only one night. The digital video recorder in Mr. Greenwald's office allows him to see the production of three VMC vertical machining centers in the workshop and the working scene of the whole workshop (Figure 1)
the digital video recorder in Mr. Greenwald's office allows him to see the production of three VMC vertical machining centers in the workshop and the working scene of the whole workshop
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