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LanSharc™ Smart Digital Controller
LanSharc™ Smart Digital Controller
 
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ePIG more info

"A single installation of 16 ePIG's at an auto manufacturer's single spindle transfer line operation has provided well over $1 million of savings in part quality, avoided down time, minimized scrap, and reduced maintenance costs in just the first year of operation."

Gauging is a critical step in ensuring manufacturing quality and consistency. While gauging is at best done by automatic systems, it is still often done by manual collection of data. Typically, in-process gauging is expensive and done only at critical steps of the manufacturing process. As a result, most common machining operations are not monitored and controlled. Dozens, hundreds or even thousands of unacceptable parts can be produced before the next "spot check" along a line catches a problem condition. Flaws are often a result of a process problem (broken/dull tool, speeds/feeds, loss of lube or coolant, etc), part problem (hardened material), or simple operator error (tool mount, etc). In most cases this change of condition from "good" manufacturing to "bad" can be captured and validated with a simple dynamic process Integrity Indicator (I²) based on a "cutting energy" signature. The ePIG system, based on the SDC003 LanSharc™ hardware platform, uses statistical analysis to alert the machine operator that an alarm condition exists where the cutting energy has changed from the expected. By using variances from the expected results, ePIG can also accommodate processes with evolving cutting energy levels (such as those with tool wear and tool change) without false alarming. By providing a trustworthy process alert, ePIG has earned the respect of both machine operators and process engineers alike.

Using a simple, non-intrusive vibration sensor, ePIG measures and analyzes both the cutting energy during a machining cycle and also the ambient rotating energy while the machine idles. During machining, the trend of the integrity indicator provides a clear signal for monitoring a "significant change in the manufacturing process". To determine what caused the change in the process, the I² trend can be analyzed either at the machine by downloading data to a PC, or by remotely addressing the ePIG system over Ethernet.

Download the ePIG™ Datasheet


Benefits

  • Improves part quality and consistency, directly related to customer satisfaction and machine reliability
  • Extends tool life and reduces tooling cost
  • Reduces the amount of scrapped and reworked parts
  • Maintenance can be scheduled specifically for machines that are indicating a decrease in performance, avoiding catastrophic failures during production runs
  • No specialized setup required, since the performance metric is not machine dependent
  • Allows for better specification and design of machines for new line installations

Typical Applications

  • Single Spindle Operations
    - Turning
    - Milling
    - Drilling
    - Boring
    - Grinding
  • Dynamic part gauging
  • Tool life extension
  • Machine utilization
  • Process optimization

Learn more about ePIG™

Example Applications

Statistical Alarming for Machining Condition Health

Part Quality on Single Spindle Transfer Lines

ePIG/CIAB Frequently Asked Questions

General Questions Answered


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