Rigorous optimisation with intelligent tools

In the automotive industry, its target sector, the company has established a reputation through holistic process coverage and products having high levels of quality and precision.

The company now employs a 90-strong workforce, and with its solid internal training, the company is gradually introducing its next generation to the challenges of the future. Leading edge 3D CAD workstations are just as state of the art as modern machinery across an area of 1,700 square metres.

For eroding applications, two Challenge 3 machines from Agie (GF Machining Solutions) are also connected to the CERTA system. Furthermore, the Venturion 450 setter station from Zoller and the Faro Gage index arm are integrated into the CERTA system. Seamless control of the entire production process means tools are also managed intelligently.

On the internal tool magazine of the relevant machine, the technician checked whether all of the necessary tools are available and that they are clamped in the correct holder. The protruding length required was also checked.

The technician then fetched any missing tools from the tool crib and filled the tool magazine manually. If the tool and holder combination was not in stock, the tool had to be shrunk accordingly into the holder whilst observing the correct protruding length, and be dimensioned on the presetter station. Attention of course also had to be paid to the correct tool being shrunk and dimensioned.

The measurement data from the presetter station was printed out and re-entered on the machine. When the tool was exchanged into the tool magazine, the magazine position number and tool then had to be transferred manually to the machine. It is self-evident how unproductive, but most of all how susceptible to errors, this process was in the past. An incorrect tool in the magazine or an incorrect protruding length can result in major financial loss – on the tool to machine or the tool spindle.

Now the CAM system accesses the relevant data, meaning all available tools are known, including holders and the current protruding length. The seamless integration of the Zoller setter station means all new, adjusted tools are added directly to the CERTA system. Magazine positions and tool holders have a bar code (data matrix). The new tool is placed into any free magazine position. This can be in the internal magazine of the machine tool or in another, external magazine.

Unique assignment to the CERTA system is guaranteed with simple scanning of the bar code (data matrix) on holder and magazine position. The JobManager from CERTA is started once the component to machine has been exchanged into the machine. In the process, the CERTA system checks that all tools required are available. The tool life is also included in the check.

If a tool has reached its end of life, it is indicated accordingly by the system, the tool is inhibited for subsequent jobs and the technician removes the tool from stock. The wear of a tool is measured regularly in the machine and compared with the tolerances in the CERTA system. When a tool breakage occurs, the CERTA system checks whether an identical twin tool is available. This renders possible a smooth and virtually uninterrupted production process. Searches for tools required are also consigned to the past as the CERTA system knows the exact storage location of all tools.

Many manual actions that have no value-add and are susceptible to errors have been eliminated here. The correct tool with the required protruding length in the correct magazine position is now reality – automated, transparent and paperless.