TMAC

tool monitoring adaptive control

Tool Monitoring Adaptive Control (TMAC) measures tool wear in real-time and uses Adaptive Control to automatically optimize feed rates through variations in material cutting; to maximize tool life and reduce cycle time.

Adaptive Tool Monitoring System for CNC Machining

Tool monitoring for CNC machining is essential for protecting the machine, maximizing tool life, and reducing cycle time. Caron Engineering's adaptive tool monitoring system, TMAC 3.0, is a real-time tool wear and breakage detection system, with adaptive feed-rate control capability. TMAC interfaces directly with the CNC control and uses high precision sensor technology to optimize machining and make real-time corrective adjustments through material cutting. The data collected by the TMAC adaptive tool monitoring system gives detailed insights to optimize cutting programs, to immediately increase performance.

TMAC will help you meet the demands of today’s competitive manufacturing environment.

Optimize Machine Tool Cutting

Caron Engineering's TMAC system uses high-precision sensors, a dedicated high-speed data processor, and intuitive HMI to measure tool wear and give real-time control over your cutting operations. By using the learned cutting data and defining thresholds, TMAC will calculate tool wear during cutting and automatically expire a tool when excessive wear is detected or issue a signal within 5 msecs to stop the machine and retract the tool in the event of breakage.

By accurately monitoring tool wear in real-time you can prevent unplanned equipment downtime and stop potentially catastrophic events in their tracks.

This real-time control is ideal for achieving lighter and unattended operations.

Tool Wear and Breakage Detection

TMAC measures tool wear and detects breakage by monitoring true spindle motor power. TMAC learns the optimum power for each tool and cutting section, and compares it to the user defined limits to calculate wear as the tool is cutting. It operates on the principle that the power required to cut a part increases as the tool’s cutting edges deteriorate

Monitors and reacts to tool wear in real-time
Uses multi-range sensors with auto-scaling display sensitivity
Prevents tool breakage and lowers scrap rate
Reduces the cost of consumable tooling
Provides valuable information about the cutting process
Stops the machine instantly in the event of tool breakage
Shows real-time data graphing as the tools are cutting

Adaptive Control Feed Rate Optimization

CNC machines are typically programmed for the safest feed rates to accommodate the worst machining and material conditions.

TMAC adaptive control learns the optimum power for each tool and continuously maintains a constant tool load by automatically adjusting the feed rate in real-time. TMAC increases the feed rate through low power cuts and decreases the feed rate through high power cuts and as tools wear.

No operator intervention required!

SYSTEM fEATURES

The new TMAC 3.0 offers an intuitive user interface designed to handle the complexity of the software while providing simplicity for the user. The web-based UI has completely customizable user views with a dynamic display that can be accessed from any device (including smart phones) and allows monitoring multiple processes and even multiple machine channels simultaneously.

Data Analysis

TMAC saves and records all cutting data. This data allows the user to interrogate specific areas of the cut to look at anomalies in the normal cutting operation. If a tool uses inconsistent power over the same cut, the user can overlay these cuts to see what is causing any anomaly. This information can also give TMAC users insight into tool life comparison between different tooling vendors and regrinds

TMAC Data Viewer

TMAC Event Viewer

Monitors and reacts to tool wear in real-time
Uses multi-range sensors with auto-scaling display sensitivity
Prevents tool breakage and lowers scrap rate
Reduces the cost of consumable tooling
Provides valuable information about the cutting process
Stops the machine instantly in the event of tool breakage.

TMAC Event Viewer

Displays detailed information for all events (starts, stops, alarms, etc.)
Custom events can be created to call out specific points in the cutting operation
User can apply custom filters to view, sort, and export events for analysis

What Else Can TMAC Do

Bearing Analysis

Signature Analysis

A vibration sensor can be attached to the spindle, hardwired to TMAC, with the bearing analysis initiated in the CNC part program.

Find out more

Signature Analysis

Using the signature analysis mode, TMAC learns the entire path (signature) of a cut using any sensor type.

Find out more

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PRIME TECHNICAL SERVICES, INC.

17295 Foltz Pkwy, Suite A, Strongsville, OH 44149

866-916-0132