Identifying machine anomalies using vibration

Caron Engineering’s newest product, DTect-IT, was developed from customers’ need to easily detect bar feeder vibration near the main spindle on a lathe. If a bent bar is introduced to the bar feeder, it will have excessive vibration. Using DTect-IT and attaching the vibration sensor somewhere near the main spindle, the vibration can be detected. The vibration level can be sent to the CNC control in a macro variable to be interrogated. If vibration is excessive, the spindle RPM can be reduced until the vibration level is acceptable to make good parts. If the RPM has to be reduced too much, and parts cannot be cut, an alarm can be generated to inform an operator to remove the bar. DTect-IT can help save valuable time and money by eliminating manufacturing bad parts from a bent bar.

Detecting bar feeder vibration is only the beginning for this new application. DTect-IT can monitor vibration of any part of the machine tool or fixture to detect vibration anomalies anywhere on the CNC machine.

Simple to install, the USB sensors can attach to any area of concern on your CNC machine, and the sensor data is instantly graphed on a display PC. This application runs standalone or integrates with the CNC control, allows the user to set limits, and connects to any Windows PC with an available USB port.

DTECT-IT ADDITIONAL SENSOR OPTIONS

Strain Gauge Sensors can be connected and used to measure very small amounts of force. This can be used to monitor the force of machine tools or components so that corrective action may be taken.

Analog Sensors - Using an analog input sensor, DTect-IT can monitor 0-10v analog signals and 4 – 20 mA current signals. This allows for monitoring power, pressure, coolant flow, etc.

ADDITIONAL MONITORING MODES

In addition to limit analysis, DTect-IT can monitor using the following analysis modes:

Bearing Analysis - By measuring spindle vibration, DTect-IT can monitor bearing health for analysis. The vibration signal analyzes the (1) acceleration value which indicates the health of the bearings, and the (2) velocity which detects misalignment, imbalance, or looseness. This application will generate and save reports over time for analysis.

Fault Detection - Using a vibration sensor, DTect-IT will recognize when set control limits are exceeded, identifying an excessive condition, such as machine impact, overheating, or excessive vibration. This application indicates and timestamps machine faults, and records data on either side of the fault for analysis.