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By enabling the licence bit #9 ( E65 22100 ), a ToolScope can be extended with a monitoring strategy in accordance to the term "Power monitor" in the GEP11TF12.

This is a special wear monitoring procedure, which is not generally of interest to users outside the aerospace industry.

To use this function, you must select "GEP11TF12" in the "Monitoring" selection field for a monitoring channel in the configuration settings.

The procedure monitors a signal against two fixed limits. These are drawn in behered and yellow in accordance with their designation in the GE Standards (Red Limit, Yellow Limit). Because GEP11TF12 assumes limits in mV, all signals are converted by a virtual amplification box to millivolts. The amplification factor which converts between the raw signal and the mV can be configured per process.

 

Configuring the GEP11TF12 monitoring procedure

 

Configurable parameters

In the left-hand area, use the drop-down menus in the "Sensor selection" area to select a trigger and a monitoring value. The "Trigger" channel describes the signal upon whose occurrence the monitoring will be activated (flank change from 0 to 1). The "Monitored signal" channel describes the signal to be monitored.

In the right-hand area, use the "Process selection" field to select the process whose settings are to be displayed. Below this, the individual parameters of the respective process are displayed.

The following parameters can be changed manually:

 

Function name

Description

Monitoring active

 

The checkmark next to "Monitoring active" specifies whether or not any alarms are to be issued for the process in question. If no checkmark is set here, the process is known to the monitoring and is observed, but no alarms are issued.

Red limit (emergency stop with tool retraction)

Here, you can enter the desired limit value for the Red Limit. The monitoring immediately issues a "Red Limit" to the control system when the Red Limit has been exceeded. As specified by GE, the limits are entered in mV.

Yellow Limit (wear limit)

Here, you can enter the desired limit value for the Yellow Limit. If the Yellow Limit has been exceeded during a process, the monitoring issues a wear alarm to the control system after completion of the process. As specified by GE, the limits are entered in mV.

Amplification factor

As many signals in ToolScope are available in different units, conversion between the measuring signal and the signal displayed in mV is carried out in accordance with a configurable and process-dependent amplification factor. This can be configured manually here.

Manual offset compensation

This function makes it possible to define the start and end of the respective signal manually. If no "measuring axis" is specified, then the measuring points relate to the time axis. If a measuring axis is specified (typically a position axis), then the information relates to the values of the position axis. This checkbox and the fields below it are only available if the checkbox "Compensate signal offset" for this monitoring channel is enabled.

Relearn; number of processes

As soon as the checkmark is set next to "Relearn; number of processes" and the process is observed the next time, the monitoring forgets the previous data and relearns the newly entered number of processes.

 

When you press a softkey in the "Configuration" view, the device makes a suggestion for the Red Limit, the Yellow Limit and the amplification factor, in accordance with the standards.

 

Monitoring learning

Start the NC program. Press the "Switch on learning" softkey if you already have data for the process in question and wish to delete these explicitly.

Run your process with the three different measuring series suggested by GE. Press "Configuration" to switch to the configuration view.

Each process, which you have learned but which is by now not configured should look like this:

 

Now either enter manually calculated amplification factors and limits or press "Additional options" and then the "Learn as reference" softkey.

(Perhaps you have to click here in between "Back to history", at latest afterwards, click the below "Teach as reference")

 

After you have pressed "Teach as reference",

  • the monitoring will suggest meaningful values for the Yellow Limit, the Red Limit and the amplification factor. In doing so, it assumes that the three measuring series suggested by GE have been done. The monitoring sets its limits and the amplification factor so that the Yellow Limit is 100 mV and the Red Limit is 300 mV above the respective limit. The amplification factor is set so that 100 mV corresponds to 20% of the critical signal height:



    If at the time where "Teach as reference" was pressed, there were defined limits, there will be a warning message, that the limits were not recalculated and that you have to reset them to 0.0 first. If you see that message, you have to set the limits to 0.0, if you want the ToolScope to calculate new limits.
     
  • the monitoring will write a calibration CSV-file. It will note the time, date, limits and amplification factors. This happens independently from the question whether limits were defined before. So this enables you to write limits manually in the monitor and afterwards generate a protocol about the procedure. The CSV file contains all relevant protocol values in an unformatted state. The file can be directly opened in Excel. If you do so, you find at about the following:

The "Sensor data" display shows in red the average value curve for process forces that were determined in the last monitored processes. The Red and Yellow Limits are drawn in as continuous red and yellow lines.

Different behavior of red and yellow limit

Please be aware, that the red and the yellow limit react differently. According to the specs in GEP11TF12, the yellow limit is hold back till the monitored process ends. The red limit is given directly to the control.

 

Behavior when a yellow limit limit occurs (alarm is hold back), and when a red limit occurs (alarm is handed out to the control directly)

Configuration of alarm retention / time threshold

GEP11TF12 suggests a configurable alarm retention. In the ToolScope, a compatible alarm retention can be configured per monitoring window (follow the link).

Behavior with activated offset compensation/zeroing

For monitoring channels in which monitoring is carried out in accordance with GEP11TF12, the "Offset compensation" function can be activated. This ensures that, at a specific time after the start of a process, the signal height is "zeroed".

Before creation of the figure below, it was configured that 1 second after the start of the process, the mean value of the last 200 ms would be calculated and deducted from the signal from this time on.

 

Process view with offset compensation

 

If offset compensation is activated through setting of the checkmark next to "Compensate signal offset" in the backend, two further parameters will be displayed in the configuration view for monitoring in accordance with GEP11TF12:

 

Function name

Description

Offset interval, start [s]

This parameter specifies the time at which offset compensation should begin.

Offset interval, end [s]

This parameter specifies the time at which offset compensation should end.

 

Process view with extended functions

Choice of amplification factor

The amplification factor can be freely chosen. As long as the amplification factor is "1", the unit at the y-axis will be the unit of the original sensor signal (see mouse cursor in the below images). As long as the factor does not equal "1", the signal behaves like it would measure a sensor value through an measurement amplifier and the unit "mV" appears.

 

Coolant monitoring / Spindle speed monitoring

The here described software of the ToolScope only provides a "Power Monitor" by the means of a GEP11TF12. Beneath the power monitoring system, the GEP11TF12 enforces a coolant monitoring. Further it enforces a monitoring of the spindle speed.

Both aspects are done by modern machine tools out of the product standard. We recomment, that you use the machine standard functions to monitore these aspects.

If you want to use the ToolScope for that, please use the Minimum / Maximum monitoring methods.

Use of true digital true power instead of analog true power sensors

Remark: you can use a digital true power sensor, instead of a seperate measuring device. The profibus and profinet drivers of the ToolScope understand to configure the compile cycles TPM and ADAS properly, if you configure the true power as input signal as shown in the screenshot below.

Tool retraction

GEP11TF12 demands a tool retraction after a red limit occured. KOMET Brinkhaus only triggers this function in a machine tool. At maximum KOMET configures that an NC program is started which can do the retraction. The responsibility for the retraction program is at the NC programming department of the customer (simple reason: we can't guarantee, that the retraction does not lead to a collision under later circumstances. The NC programming department has to take care of that aspect.)

Clearance / Usability on different version of the ToolScope firmware

The GEP11TF12 methods have to be cleared manually per version of the ToolScope firmware. The actually latest cleared version is V10_SP14.1 with a special hotfix (branch V10_SP14 till 2017/04/28). Please use exact the combination of the mentioned firmware and the attached hotfix to get the above results. Other versions should work but are not cleared.

Attachments

SoftScope settings which were used to generate the above images

Hotfix to gain the above results (has to be installed on V10_SP14.1)