Optimizer4D

Physics

A Block of steel reveals micrometer sized crystallites in the fine-structural area that make up its composition. Now, when a blade cuts, it tears off those crystallites – a cascade of microcracks sends high-frequency impulses through workpiece and tool. Something similar happens in welding: the material is melted and then qickly hardens afterwards, so the crystallites in the structure merge and tear again, causing shock waves.

Signal acquisition and signal processing

The shock waves run through the clamping device or the connected tool and induce shock waves to the coupled machine parts. These are detected by a sensor, intensified in a preamplifier and forwarded to the measuring computer. Thanks to the Optimizer4Ds extremely high sampling rate, events can be detected to the microseconds range.

And this is essential. Because the faster the machining and the finer the structure, the faster the shock waves follow one antoher and the higher the maximum oscillation frequencies get.

At this, not only events on the surface are being perceived, but events that take place deeper in the material as well: the Optimizer4D allows a view inside the machining process, in drill holes and under cooling liquid.

Display and data analysis

The Optimizer4D converts the oscillation signals into a three-dimensional process image that shows the signal intensity in time and frequency. Every production process like metal cutting, drilling or welding creates a typical landscape which form gives us information on the changes in the materials structure.

High impulse waves indicate high machining force. If the process landscape is lower and less rugged, the average cutting force is lower and the cutting process even. Generally speaking, it is good to have low maximum forces and low variations in stress between blade and material.

Furthermore, the process landscape displays material- and process features and gives information on cooling liquids, lubricants, material hardness, rotational speed and front rake angle, the number of microcracks in the cooling phase in welding and much more.

Process regulation

If the process image changes from one frame to another, this means, that an actual change in the production process happened. A defective weldseam or a worn out or broken tool can be detected this way. Those changes can be can be used for process regulation: Freely adjustable limit values allow for fully automated supervision/regulation of the cutting- and welding quality or tool wearout. The Optimizer4D communicates directly with the machine via IO-Interfaces (addition interfaces: e.g. Profibus; IO-digital; Profinet…) which enables it to send messages like “out of order” or point out the necessity to change a tool.

Optimization

The Optimizer4D can supervise your process fully automated. But it can be used as an expert system as well, to determine optimal process parameters for the machine. Every change in the parameters affects the process landscape, which gives information on the cutting performance. High value occurences at unusual positions, like when pulling out the drill, can be interpreted and the parameters be altered accordingly.

An overview of the facts

• Fully automated process supervision for a variety of production processes: Cutting, drilling, reshaping, induction-hardening, welding.
• 50 MHz sampling rate over up to 4 measuring channels.
• Up to 8 preamplifiers and 48 sensors per unit.
• Storage of the measuring data (up to 80 MB/s and channel) on removable media (up to 8 TByte) subsequent analysis or archiving.
• Touch-Display to display and operate.
• 24V io unit for direct communication with the machine contols
• Profibus connection available
• Extensive software with many analysing tools, which also allows for automated process regulation.