How It Works
Process observation and Process monitoring

Many influences determine the quality of the product

This picture shows a production machine schematically. This machine manufactures one part with one or more tools. Of course the product is most important of all. It should be produced quickly at low costs. And the quality should be good.

Many components have an influence on the quality of this product.

The material - The material differs sometimes
The machine - The machine can be old or new. It may be in a good condition or needs maintenance.
The tool - Especially during cutting processes tools have to stand high demands and heavy loads. Thus the condition of the tool is important for the quality of the product.
The cooling - Bad cooling agents can cause quicker wear or even severe damage to the tool.
Environmental conditions within the production hall or the location of the machine determine the process.
Human - Last but not least, human has great influence on the process. Is the worker motivated? Is he well-trained? The setting of the machine depends very much on the worker.

Firstly he may use his senses. He can see. He can try to observe the process although it is hard sometimes even impossible.The experienced worker knows that it is almost impossible to see the tools during the cutting process due to cooling. His second sense-organ is his ear. To hear is important for process observation. In fact, background sounds in the production floor and the cabin of the machine make it difficult to hear. Only loud noise like collisions or crashes are audible. The third possibility is to measure the product with adequate measuring instruments. Depending on the product a great range of sophisticated measuring instruments are available. Random samples and gauges are the usual tools of the worker to measure.

Process observation with sensors The worker can not see, hear and measure everything. To enhance his capabilities he needs special instruments. Brankamp offers those special measuring instruments. Sensors are mounted close the the process to measure all process relevant parameter. The most important parameter is the process quality. We call this important parameter the PQ factor. The PQ factor is shown on the control system. This allows the worker to conclude on the process behavior. He can intervene or optimize if necessary.

Process observation of trend An enormous enhancement for the worker are monitoring systems, that do show not only the actual process value, but visualize the process and the behavior of the PQ factor over a certain period of time. Let´s compare it with the price trend of the dollar. To judge whether the dollar trend is good or bad demands an observation of a longer period of time. Our graphical displays offer a look insight the process. Its the workers window into process.The benefits of process observation for the worker

What are the benefits of process observations for the worker?

• A good look into the process
• Visualization of the process
• Quick intervention in case of deteriorations  or changes
• Optimization of tool installation
• Trend information
• Tool protection
• Tool change on time
• Operator “learns” machine/process
• Recognition of mistakes and interference at-a-glance
• Short introduction time for new operators
• Comparison of different tools
• Optimization of process speed

Process observation leads to higher efficiency
Not only the worker has his benefits, the efficiency for the company is an even bigger bonus of process observation.

• Enhanced machine usage
• Reduction of down and maintenance times
• Reduction of set up times
• Reduction of maintenance costs
• Reduction of tool costs
• Protection of valuable tools
• Quicker set up times of new machines
• Optimize process factors
• Reduction of part costs
• Reduction of process deterioration
• More hours of operation due to production even during short absence time of the operator
• Easy multi-machine operation

Process observation and Process monitoring

All advantages named so far are a result of process observation, where the worker is the main actor and able to optimize the process or intervene into the process, if necessary. Process enhancement due to the workers observation and intervention.
On the other hand we have process monitoring. Almost all BRANKAMP units are not only able to display the process on the screen, they control the process simultaneously and react automatically. BRANKAMP monitoring systems can control the process against process limits. Our example shows 4 limits.There is first of all a upper security limits, that is set and non-changeable. Any exceeding of this limit leads to a machine stop.
Furthermore we have three adjustable production limits. These limits may give out signals according to your specific application, e.g. warning message on the screen, stop signal etc.
The limits L1, L2 and L3 are flexible changeable limits, that may be set according to the needs of the producer in order to realize an optimum process adaptation.

Machine protection from the very first day on

To sum up: With the installation of a BRANKAMP process monitoring system we guarantee a machine protection from the very first day on. This machine production is activated without any further settings. There is no need for any specific set up procedures.
There is of course an additional benefit when all the other limits are activated too. This is easy to do by the operator.

Actual process values

This masks shows the PQ factor of all connected sensors in digital as well as graphical form.

The upper sections shows the monitoring channels C1, C2, C3 and C4 with the corresponding actual process values. Below the process values for each channel are displayed as a black bar with white and black lines. The white lines indicate limit L1, the black ones limit L2 and L3 and the very right one the security limit L4.

Process Memory

Additionally each sensor channel has a so-called Process Memory.
We did see this mask already. Each of those vertical lines indicate the maximum value of the PQ factor of one part produced. The mask displays the PQ factor of the last 112 parts produced and is a histogram of the process a good look into the process. Our example clearly shows the trend, that may be a result of tool wear.
There is also a process variation visible. And of course the intervention limits L1 , L2 and L3 are clearly shown. You can see that a process value has almost touched the limit L2. Due to the sophisticated program of our units overshooting's must not necessarily stop the machine stop or send out a warning. A certain number of overshooting's may be tolerated. The operator can set the number of overshooting's to be tolerated before stopping the machine and interrupting the production. This feature is very helpful in order to avoid machine stops or warning messages due to accidental deteriorations, e.g. cramped splinter.

Tool life counter

The monitoring system provides a tool life counter, an optional software for cutting processes. This software can supervises up to 24 tools.
Total is the total tool life quantity, i.e. the number of parts one tool can produce.
Actual is the number of parts already produce so far.
Rest is the calculated tool life.

Productive counter

The monitoring unit has also a so-called productive counter, counting the number of parts produced.
Please note, the counter counts parts not cycles. As there are sensors mounted in the machine measuring the forces, we can tell whether the force was to low or in range to produce the part. Any idle run will be neglected by the productive counter.
The method of the productive counter is equal to the tool life counter. Input the total order and the monitoring unit will automatically display the actual number of parts produced and calculate the rest. In case the machine produces more than just one part per cycle the input field "FACTOR" offers the possibility to set the number of parts produced per cycle.

Stop/Go-Diagram

The monitoring units provides an optional software called ASR - Automatic Stop Recording.
 It works similar to a black box. Sensors can tell whether a machine produces or stands still or even if the operator is setting up the machine. This is shown on the mask "STOP & GO DIAGRAMM" over the last 10 hours at a glance.
Furthermore this feature is helpful when changing shift. The diagram can also be used as a shift report. The following shift gets an overview of the machine operating times and can easily handle further production.

Stop-Code-Memory

Further information about stops are stored and displayed on the mask Stop-Code-Memory.
The date and time of a stop and the corresponding channel are displayed. Furthermore the reason of the stop is indicated, i.e. whether L2 or L3 have been exceeded or if the PQ factor was under the intervention limit L1.
 Please note, that all these information is shown by pressing just one button.Of course it is possible to network all monitoring units and transfer the data of each monitoring unit to a personnel computer. To do so we use the software DC 5000.

Summary

• Start quickly, but considerately.
• No matter, whether you start with new or old machines. It is important to start at all.
• It is crucial to start with the most motivated operators.
• Equip groups of machines. Not just one out of a group.
• Our monitoring systems are measuring instruments for all processes. And every worker needs some kind of instrument to measure or control his production.
• Equip larger areas to increase the benefit. Then, the know-how is available for the whole production.