A customer has a Tsugami lathe, running unattended, with an auto-fed barfeeder delivering 12-foot bar stock to the machine. This customer was scrapping a significant amount of parts due to irregularities in the bar causing dimensional and finish errors.
The customer mounted a Caron Engineering DTect-IT vibration sensor to the barfeeder and connected it to the Fanuc control to monitor certain characteristics of the lathe program. The customer set the vibration thresholds and then programmed an acceptable RPM range for compensation.
While parts are machined, DTect-IT monitors the vibration levels on the barfeeder. If vibration is within the acceptable limits, nothing is changed. If vibration levels exceed the user-defined limits, DTect-IT alerts the CNC control to reduce the spindle RPM within the acceptable range to compensate for the excessive vibration. DTect-IT will then inform the CNC control when the vibration levels are (1) acceptable or (2) generate an alarm to stop the machine if the RPM must be reduced beyond the lowest threshold to make good parts.
Using DTect-IT, the customer has eliminated scrap parts due to irregularities in the bar stock. Excessive barfeeder vibration also has a negative impact on bearing life. With DTect-IT monitoring the vibration, they have realized the additional benefit of increased spindle life.