Manufacturers across the globe are experiencing numerous challenges with the most predominant among them being the prevalent skills gap of potential employees, the increasing process complexity, and integrating robotics or automation systems. There is no question that manufacturers are quickly pivoting strategies, equipment, and technology to adapt to a more wholly automated future. While the expected throughput for these manufacturers continues to rise, innovative technology from Caron Engineering can address these challenges and create the ideal environment for what is known as lights-out machining.
Lights-out machining refers to the state of operation in which machining operations are completed with minimal human intervention thanks to the assistance provided by fully automated manufacturing technology. Implementation of lights-out machining solutions subsequently improves the quality and efficiency throughout the production process. Caron Engineering has spent years developing the ideal slate of manufacturing technology for lights-out manufacturing. When this technology is successfully integrated manufacturers gain the capacity to run complex cutting operations with far less human interaction than previously possible. Continue reading here to learn more about the six unique manufacturing technology products offered by Caron Engineering, how they contribute to a state of lights out machining, and the extensive network of integrators qualified to make lights-out machining a reality for your company.
Caron Engineering Manufacturing Technology
Achieving true lights-out machining capabilities at your facility may require the complete arsenal of Caron Engineering manufacturing technology. Each technology system is a critical component of lights-out machining solutions and successfully optimizes productivity, quality, and precision across all manufacturing sectors within your facility no matter the complexity.
MiConnect Technology: MiConnect Technology software is a flexible application builder used to design customized automation and process control solutions specific to a customer’s operations or industry. MiConnect takes control of the device communication and interaction in your manufacturing environment without the need for custom coding. The prebuilt devices (CNCs, robots, barcode scanners, I/O, Modbus, files, SQL, REST API, etc.) already exist in the software and interactions can easily be customized and controlled to fit your process requirements using a drag-and-drop design infrastructure. MiConnect is vital to the pursuit of lights-out machining as it can minimize operator decisions by making pre-programmed decisions based on certain condition results without necessitating operator interaction. MiConnect Technology is also an invaluable tool for controlling the remaining human process interaction using custom status screens and guiding the user through clearly defined operational steps before allowing subsequent processes to take place.
- TMAC (Tool Monitoring Adaptive Control): Now in its third iteration, TMAC 3.0 is a tool wear and breakage detection system that delivers real-time adaptive tool monitoring and is essential to attaining lights-out machining capabilities. With a direct interface to the CNC and a dedicated high-speed data processor, TMAC takes control of the cutting process to make automatic, real-time adjustments during cutting. TMAC monitors true spindle motor power and identifies the optimum power for each tool and cutting section. This information is then compared to the user-defined limits to calculate tool wear in real time as cutting takes place to protect the machine, maximize tool life, and reduce the cycle time of complex components. TMAC automates the cutting process by allowing you to walk away, knowing it will take action if anything outside the normal cutting parameters occurs. Integrating TMAC into your manufacturing environment will avoid unplanned equipment downtime, reduce cycle time, stop detrimental events from occurring, and afford unattended cutting operations required to achieve lights-out machining.
- ToolConnect: ToolConnect is a machine tool data management system capable of eliminating human error and reducing machine tool setup time by automating the transfer of presetter-measured tool data to and from the CNC control. Instead of relying on time-consuming manual data entry prone to human error, ToolConnect uses an RFID system to read and write data directly to the CNC control including the necessary tool offsets and tool life data. ToolConnect creates a uniform user interface for all CNC machines on your shop floor and provides a consistent and accurate procedural flow to automate the process of loading CNC tools, necessary for lights-out machining.
- AutoComp: AutoComp is a Windows-based software application capable of reading and processing part measurements from nearly any electronic gauging device. AutoComp determines the required tooling adjustments, and updates the offset settings inside the control. All of this happens automatically without requiring operator intervention that can introduce manual data entry errors, and further streamlines production by notifying operators when a tooling change is required. AutoComp ensures consistent quality of finished parts and closes the loop with automated compensation calculation and feedback to the CNC, an essential piece for lights-out machining.
- DTect-IT: Caron Engineering’s DTect-IT CNC Sensor Analysis System merges high-precision machine tool sensors with an advanced analysis capability to detect and correct any anomalies that arise during the machining process. Whether you’re looking to detect and correct vibration issues, determine if a collet is clamped correctly, or have runout issues, DTect-IT offers manufacturers several analysis types to best fit their CNC machining processes, including limit analysis, spindle bearing analysis, fault detection, frequency analysis, signature analysis, and data collection analysis. With an advanced historical data viewer, DTect-IT allows companies to thoroughly analyze, compare, and identify machining trends over time to prevent unplanned downtime.
- Smart Light System: While a Caron Engineering Smart Light System is not a mandatory requirement for manufacturers looking to achieve lights-out machining capabilities it can be an incredibly beneficial tool. The completely customizable Smart Light System provides an immediate visual representation of the various stages, statuses, and possible complications that can arise during the operation of CNC machining equipment. This visual identification process significantly reduces the need for hands-on inspection methods that necessitate additional personnel and time. Using the CEI Smart Light System, you can see the status of all CNC machines at a glance, allowing a single operator to effectively manage more machines simultaneously.
Reasons To Implement Lights-Out Machining Solutions
The goal of any manufacturer pursuing lights-out machining solutions is to limit human interaction throughout the manufacturing process and directly improve the overall efficiency, accuracy, and throughput of their facility. With persistent obstacles like skills gaps, complicated technology, and general availability of qualified operators or technicians, the integration of Caron Engineering technology provides manufacturers with the following advantages in their pursuit of lights-out machining solutions.
- Improved Productivity & Efficiency: All Caron Engineering technology is designed for automation to improve the productivity and efficiency of manufacturing processes to achieve lights-out machining. From the Smart Light System identifying machining stages for floor personnel to the tool-cutting optimization power of TMAC, each piece of technology will provide an immediate lift to the productivity and efficiency of your business.
- Comprehensive Monitoring & Control: All of Caron Engineering’s advancements in manufacturing technology are focused on bringing a greater sense of understanding and control throughout your facility. With user-friendly interface designs and instant accessibility, achieving a state of lights-out machining at your facility has never been easier. Manufacturers can now make immediate adjustments throughout the manufacturing process to improve efficiency metrics and meet evolving quality standards.
- Cohesive Device Communication: Establishing a comprehensive communication network across the various complex devices found in manufacturing environments is paramount to successful lights out machining. MiConnect Technology Software offers customers the capability to create a unified network that offers incredible control throughout the manufacturing process. Currently, no other available technology streamlines device communications with a singular piece of software quite like MiConnect.
- Reducing Cycle Time: A primary focus for any manufacturer integrating lights-out machining solutions from Caron Engineering is reducing cycle time. By eliminating the need for continual human intervention, establishing a uniform communication network, and implementing the appropriate systems to make automatic process adjustments in real-time, manufacturers are reducing their cycle times and producing more quality components in less time.
- Streamlined Labor Force: With less manual intervention required throughout the machining process, companies can machine more material with fewer required operators. Furthermore, establishing a uniform user interface across the entire fleet of CNC equipment with MiConnect, TMAC, or ToolConnect simplifies the training of new employees. Caron Engineering technology can help manufacturers better understand their specific needs as they face labor shortages and skills gaps.
- Enhanced Quality & Consistency: The numerous analytical and information-sharing resources available through Caron Engineering are all essential to the enhanced quality and consistency paramount to successful lights-out machining operations. Companies that have successfully integrated one or several of Caron Engineering’s solutions have seen significant improvements in the quality and consistency of machined components. An excellent contributor to improved quality is TMAC, as it continually monitors to keep cuts within the established thresholds while simultaneously diagnosing tool wear and taking in data from other sensors such as vibration, spindle speed, and coolant flow, to monitor other essential machining processes. CNC Machines equipped with TMAC fabricate with exceptional precision and significantly reduce the possibility of scrapped components or wasted material.
- Continuous Machine Run Time: Lights-out machining solutions expand manufacturing output beyond the standard first or second-shift hours. Caron Engineering’s proven manufacturing technology improves the trust business owners have that CNC machines can maintain strict tolerances, catalog essential data, and operate without risk of damage to material or machines after normal operating hours. Not only that but continual machine run-time separates manufacturers from the competition and allows greater throughput and reduced costs without risking final component quality.
Finding An Integrator of Caron Engineering Technology
Caron Engineering recognizes the importance of offering highly qualified integration services for our smart manufacturing technology to companies pursuing lights-out machining solutions. That is why we’ve established a comprehensive international network of qualified companies that specialize in the integration of our technology. Their intricate understanding of TMAC, AutoComp, DTect-IT, ToolConnect, MiConnect, and Smart Light Systems will immediately upgrade the efficiency and operational capacity of your business as you progress towards lights-out machining. Streamline and stress-free integration into your CNC systems ensures that your facility operates at optimal performance levels before, during, and after the cut while providing the confidence you need to move towards around-the-clock machining.
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