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製程前設定

使用測頭進行自動設定可比手動方式快達 9 倍。

Productive Process Pyramid™(金字塔生產製程解決方案)製程前設定層的控制元素在開始切削前便建立了工具機、工件與刀具之間的關係。這些自動化、預知型控制確保了首件成功率。

確保首件成功率

金字塔生產製程解決方案 - 製程前設定 Productive Process Pyramid(金字塔生產製程解決方案)製程前設定層乃處理製程中的不確定因素的來源,例如工件的位置、刀具的尺寸及機械偏置,根據工件實際位置調整加工。

這些是應用於金屬切削即將開始前的預知型控制。

刀具設定建立 …

  • 加工機上的OTS 距主軸量測線的長度,以確定高度補償並檢查長度是否在指定的公差範圍內
  • 旋轉時的直徑,以確定刀具尺寸偏置

工件設定建立 …

  • RLP40接觸式測頭 工件識別,以選擇正確的 NC 程式
  • 基準特徵位置,以建立工件坐標系 (WCS)
  • 坯料/工件尺寸,以確定餘量狀態和粗切削順序
  • 工件的方向(相對於工具機軸),以創建座標旋轉

工具機設定建立 …

  • 5軸工作臺上的AxiSet Check-Up球 工件定位與裝夾所需的旋轉軸、轉台或夾具組件的基準校準
  • 轉台的旋轉中心位置和/或夾具元件上參考點位置

預知型控制

使用測頭進行自動設定,可比手動方式快達 9 倍,因此能夠節省出更多的時間用在金屬切削上。

測頭量測也可預知 — 您可以計算出檢測設定所需的時間,因此可以事先制定計劃。

通過機上測頭量測技術進行製程前設定時,完全由程式控制,因此不再需要專業技術人員執行多種量測、計算及輸入偏置修正等工作。

Renishaw 工件檢測測頭、刀具設定系統及 Productivity+™ 軟體是快速、自動、可重複設定金屬切削作業的重要工具。

高效製程模式

  • Educational article:  (AP200) Productive Process Pattern: Part identification Educational article: (AP200) Productive Process Pattern: Part identification [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to take measurements on the raw material (or previously machined features) to determine the identity of the component, the component alignment on the machine tool, and/or to check for non-conforming material.

  • Educational article:  (AP201) Productive Process Pattern: Intelligent program selection Educational article: (AP201) Productive Process Pattern: Intelligent program selection [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to determine whether the component blank loaded in the machine tool is the correct one for the machining program. Where a unique, identifiable feature exists on the component (or one can be added) a probe may be used to make a logical decision about which of the available cutting programs should be used.

  • Educational article:  (AP202) Productive Process Pattern: Part presence check Educational article: (AP202) Productive Process Pattern: Part presence check [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to identify which components are actually present and should be machined. The probing results can be used to control program logic that determines whether to machine a component or to skip machining if no part is present.

  • Educational article:  (AP203) Productive Process Pattern: Job set-up Educational article: (AP203) Productive Process Pattern: Job set-up [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to automatically measure the location of the component and update the relevant offset. Where appropriate, also use the probe to update the orientation of the component using a controller function or a rotary axis.

  • Educational article:  (AP204) Productive Process Pattern: Tool setting Educational article: (AP204) Productive Process Pattern: Tool setting [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a tool setting probe mounted within the machine tool to automatically set the length and diameter of each tool before machining begins.

  • Educational article:  (AP205) Productive Process Pattern: Tool identification Educational article: (AP205) Productive Process Pattern: Tool identification [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. An on-machine tool setting system is used to establish tool length and diameter offsets when replacing tools. As a safety check, the measured values are compared against reference dimensions with a tolerance applied: if the tool length or diameter deviation is greater than the allowed tolerance, the process will stop safely before any machining takes place or any damage can occur.

  • Educational article:  (AP206) Productive Process Pattern: Machine capability check Educational article: (AP206) Productive Process Pattern: Machine capability check [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to perform a machine capability test before machining. Commence machining only if the machine is within the capability limits defined for the component. Measuring known reference features shows the machine is capable of positioning itself accurately and repeatably, or if there is a capability problem.

  • Educational article:  (AP207) Productive Process Pattern: Clearance check Educational article: (AP207) Productive Process Pattern: Clearance check [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to test critical sections of a toolpath where interference is possible. The probe will stop when a collision is detected making it safe to perform this check: a cutting tool is not able to provide this feedback. Proceed with the machining process only after all potentially hazardous areas have been tested and probe results indicate that no obstacles exist within the tool path.

  • Educational article:  (AP208) Productive Process Pattern: Parametric programming Educational article: (AP208) Productive Process Pattern: Parametric programming [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure features which vary between parts within a given family and allocate macro variables for those feature measurements. Different parts can be produced by a family-specific rather than a part-specific program by controlling features that vary between parts using logic based on probe measurement results.

  • Educational article:  (AP209) Productive Process Pattern: Path optimisation Educational article: (AP209) Productive Process Pattern: Path optimisation [en]

    Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure workpiece condition. Apply logic based on the measured stock size to control the cutting path so that air cutting is eliminated and machining moves always cut metal.

  • Educational article:  (AP210) Productive Process Pattern: Adaptive machining Educational article: (AP210) Productive Process Pattern: Adaptive machining [en]

    A manufacturing process may dictate that the form of a finished component is dependent on the form of the input material for that process. In these circumstances, it is necessary to measure the form of the input component and use the measurement to produce a customised cutting program which is unique to that component.

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