GIORNATA DI STUDIO SU UTILIZZO DI

SENSORI PER IL MONITORAGGIO DI

MANDRINI PER FRESATURA E RETTIFICA
Usage of sensors in the spindles for
high performance cutting and precision machining

State of art and new technology

Ernst Kulli

Contents
1.

Introduction

2.

Spindle integrated sensor

3.

Case study of high performance cutting

4.

a.

SmartVision

b.

SmartDrive

Case study of precision machining

a.

DMD

b.

Shaft cooling

Ernst Kulli

Fischer AG Precison Spindles

- Founded 1939
- In the second generation of family ownership
- Location Herzogenbuchsee
- 170 Employees

Fischer Precise Group:

3 Brands 7 Locations

Ernst Kulli

Rotation

~ 4000 BC.

The name

stands for

PRECISE, FAST and POWERFUL rotation

Ernst Kulli

Quo vadis?

Precision

Speed

Power / Torque

Precision parts

Grinding

High Power

Surfaces

Small tools

High Torque

Ernst Kulli

Bearing

Ball bearing

Air bearing

Hydrostatic

Angular contact ball

bearings

Static
Compressed air is introduced

Cylinder roller bearings

and others

Dynamic
Air cushion is built up by the
movement itself

Static
Liquid is introduced under
pressure
Dynamic
Pressure in the fluid builds
up by the pumping action of
the two part surface

Ernst Kulli

Magnet

Contact free
Bearing forces is
generated by controlled
electromagnets

Contents
1.

Introduction

2.

Spindle integrated sensors

3.

Case study of high performance cutting

4.

a.

SmartVision

b.

SmartDrive

Case study of precision machining

a.

DMD

b.

Shaft cooling

Ernst Kulli

Sensors
Force flow of bearings

Motor temperature
Shaft angle position

Bearing temperature

Flow rate
Axial position of
interface
Leckage
Structure
acoustic noise
Speed

Number of tool changes

Vibration level

Ernst Kulli

Current

Voltage

Sensors

Visualize the condition of the spindle

Records the measured datas

Analysis exceeded warning levels

Registered alarms

Allows to create reports
Smart Vision

Safe operation of spindle

Optimization of the machining process

Ernst Kulli

Sensors
14

Schnitttiefe ap [mm]

12
10
8
6

Itotal = 139 mm

4
2
0
23000

F r se r 8 6 2 0 4 5 2 , D 1 6
lge s = 1 3 9 m m , la = 4 8 m m
2 S c h n e id e n , V o llh a rt m e t a ll
V o lln u t, f z = 0 ,1 8 m m

s ta b ile r S c h n itt
R a tte r n
E x p e r im e n te lle S ta b ilit ts k a rt e

24000

25000

26000

27000

28000

29000

Ia = 48 mm
30000

D r e h z a h l [1 /m in ]

14

s ta b ile r S c h n itt
R a tte rn
E x p e rim e n te lle S ta b ilit ts k a rte

Schnitttiefe, ap [mm]

12

F r s e r N r. 7 9 6 8 5 7 1 , D 1 6
l g e s = 1 6 6 ,5 m m , l a = 7 5 ,5 m m
2 S c h n e id e n , V o llh a rtm e ta ll
V o lln u t, f z = 0 ,1 8 m m

10
8
6
4

Itotal = 166.5 mm

2
0
20000

21000

22000

23000

24000
25000
26000
D r e h z a h l [ 1 /m in ]

27000

Ernst Kulli

28000

29000

30000

Ia = 75.5 mm

Sensors
Machining forces

Force [a.u.]

5 revolutions

Time [a.u.]
Ernst Kulli

SmartVision Report
Customer send his recorded SmartVision Data back
for analysis by Fischer Engineers.

You will get back an analysis of:

Productivity of the machine

Spindle power and torque utilization

Spindle speed utilization

Observations by experienced spindle experts

Recommendations for improving spindle reliability

Ernst Kulli

Contents
1.

Introduction

2.

Spindle integrated sensor

3.

Case study of high performance cutting

4.

a.

SmartVision

b.

SmartDrive

Case study of precision machining

a.

DMD

b.

Shaft cooling

Ernst Kulli

High Power Milling

Example: Aeronautical structure parts
With spindle power of over 150 kW
material
removal rate of > 15 l/min are achievable.

Fischer converter

MFW-2715/20

MFW-2320/30

for high power

150 kW, 96 Nm S1

100 kW, 48 Nm S1

Ernst Kulli

High Torque Milling

Example: Structure parts for energy
generation
High torque for roughing and high speed for
finishing are necessary to mill difficult
machinable materials with long tools

MFW-2801/16

MFW-2702/08

198 Nm, 28 kW S1

445 Nm, 93 kW S1

Ernst Kulli

SmartDrive
Strong
Current up to 300 Aeff,
sufficient for spindle power of 200 kW

Fast
Special modulation method up to
20 kHz: high torque and high speed in
combination
Current control loop cycle time 2 s
Sensor Signal processing, including
recording in 0.2 ms cycle time
[PLC Function]

Intelligent Design
One connection for all Spindle Sensors
Spindle Electronic on Board
PC integrated for monitoring of spindle sensors

Ernst Kulli

SmartDrive Process Analysis

View through the Spindle
Process Analysis of

Speed
Torque
Power
Vibration at the Cutting Edge

Integrated Oscilloscope
Highest Resolution
Detailed Information

Communication to CNC Control

Exceeding of limit values
Quick Signal variation during processing
Envelope monitoring or Teach-in Cycle

to optimise the Cutting Process

Ernst Kulli

Contents
1.

Introduction

2.

Spindle integrated sensors

3.

Case study of high performance cutting

4.

a.

SmartVision

b.

SmartDrive

Case study of precison milling

a.

DMD

b.

Shaft cooling

Ernst Kulli

o
nan

Thermal constant process condition

Benefits
1. Shortening the time until
saturation of temperature
Time reduction -80%

Spindle temperature

Shaft cooling

Without shaft cooling

Shaft cooling
Time

Ernst Kulli

Thermal constant process condition

Benefits
2. Reduction of shaft elongation

Shaft cooling

Without shaft cooling

Dilatation -70%

Shaft cooling
Zeit

Ernst Kulli

Displacement Measuring Device

Compensation of thermal and
mechanical spindle growth

Ernst Kulli

Thank you for your attention

Ernst Kulli
Senior Engineer
Fischer AG Przisionsspindeln
3360 Herzogenbuchsee
ernst.kulli@fischerprecise.ch
www.fischerprecise.ch

Ernst Kulli