Vibrations, chatter marks, tool failure – what has so far robbed many a machine operator of sleep will soon be a thing of the past: With the smart iTENDO hydraulic expansion toolholder, SCHUNK and startup company TOOL IT present the world’s first intelligent toolholder that monitors the machining process directly at the tool, and allows real-time control of the cutting parameters.
The intelligent toolholders from SCHUNK were designed in cooperation with the Vienna University of Technology and TOOL IT GmbH, Vienna. They fully use the potential of integrated process monitoring directly where the chip is formed. SCHUNK calls this strategy “closest-to-the-part,” whereby the intelligence is integrated directly into the first wear-free element of the machine equipment that is closest to the workpiece. The smart tool is offered initially in combination with SCHUNK TENDO hydraulic expansion toolholders starting in 2019, allowing complete documentation of process stability, unmanned limit value monitoring, tool breakage detection, and real-time control of the speed of rotation and feed rate.
During machining, the intelligent toolholder permanently analyzes the machining process. If the process becomes unstable, it can either be stopped in real time and without the intervention of the operator, reduced to previously defined basic parameters, or adapted until the cut returns to a stable range. The system enables complete documentation and limit value monitoring as well as an improvement of the machining quality by automatically adjusting the cutting data during vibration. Moreover, the intelligent toolholders additionally enable an analysis of the tool condition as well as increase the metal removal rate. The system is extremely easy to retrofit without the need for modification or replacement of machine components. Since the algorithms run autonomously and the operator defines only exact limit and reactions, no expert assessment of the data is necessary. Instead, the system manages the process autonomously and in real time based on the specifications.
Filed Under: Industry 40, IoT