"NC machines that run normally will eventually collide," in the machining field, although each manufacturer has strict training and emphasizes workshop safety, even summarizing a rigorous set of operating procedures, accidents still occur from time to time and cannot be avoided. Damaging tools and affecting machine accuracy are common, but if unlucky, endangering lives is even more terrifying. These are lessons paid for in blood.
●Machine Tool Airbag●
For factories, collisions have always been a major issue. The industry has been developing new technologies or methods to prevent such events - there's Mastercam and other automatic programming simulation software, machine tool manufacturers developing safety monitoring based on systems, training to improve worker quality, or formulating site operation behavior standards to constrain "people" behavior, such as "three looks, two wants, one stop." But the reality is that collisions still occur frequently. The reason is that with "people" involved, collision behavior has random and unpredictable attributes, and losses are unavoidable.
Normal Workpiece
Crashed Workpiece
Machine After Collision
The above shows a FAMAR turning-milling compound machine of a certain customer. Before installing collision protection, a collision occurred, causing the machine spindle to be scrapped, with direct economic losses of 200,000 and repair taking more than a month, seriously affecting production plans. After installing collision protection products, collisions also occurred, but no spindle overhaul or production line shutdown was caused. The following is the collision record recorded by the control box:
"This system has indeed brought us benefits. Since installation, the machine has had multiple collisions, but none caused significant losses or production line stoppage."
The workshop manager said, "We are very satisfied with the results. In the future, we plan to install collision protection on the entire production line. These are imported key equipment, and if something goes wrong, after-sales service is difficult to resolve. This investment is really worth it." We bring value to customers, and customers give feedback through repeat purchases. Nothing better illustrates the product's function.
●1ms Emergency Stop, A Miss by a Millisecond Loses the Whole Battle●
Montreal collision protection includes fully German-imported high-precision acceleration sensors, controller (black box), and monitoring software. Based on high-precision acceleration sensors to quickly sense collision behavior, it detects collisions within 1ms and sends emergency stop instructions to the machine tool, minimizing collision losses.
The IBU-NG system uses high-precision three-axis acceleration sensors to simultaneously perceive subtle vibration from three-dimensional space, which traditional sensors do not have. This conforms to the three-dimensional motion characteristics of machine tools. Only by perceiving data in space can we truly perceive abnormal collisions from any direction in space. Then through our unique hardware and algorithms, the system can collect, judge abnormal data, and send alarms to the machine within 1ms. The faster the machine receives the alarm signal, the earlier it will stop, and the smaller the loss.
Sensor and Control Box Installation Example
What We Can Recognize:
- Abnormal collisions from any direction during fast or slow feed of the machine tool
- Abnormal vibration overload, overcutting during cutting process
- Health status of machine components (ball screws, spindles, etc.)
What We Can Achieve:
- Real-time monitoring of processing process, minimizing serious losses caused by unexpected collisions.
- Real-time monitoring of machine mechanical data changes during operation, discovering processing hidden dangers usually overlooked.
- Real-time recording of abnormal data during machine operation, facilitating problem investigation and tracing at any time, achieving "black box" function.
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