How do you determine the quality of your parts? In contrast to conventional practices of inspecting the finished part for defects, our system acquire all data to monitoring the process analysed and give the opportunity, to create a warning system, capable to measure the process variance on a machine during production, thus detecting problems at the source before they become quality issues. Thanks at combined control of two magnitudes as Force vs Displacement is possible replace a waveform of the process and cheek if correspond to a product with zero defects previously loaded in the system as masterpiece to be compared with the later produced parts. The knowledge of this waveform is very important, correspond at a mathematical model to compare your products, in other words if a process is known, thank our process monitoring, you will be capable of producing only good parts, and if the process is consistent and repeatable, then the output of good parts should be consistent also. A constant control of Force vs Displacement, indicate to production management if the resulting part has not been produced according to the previously "learned" good part. By a continuously monitoring of production input experienced by the servo press equipment it is possible detect variance that can mean the process is no longer quality capable. Catching defects at the source gives manufacturers the confidence that only good parts are shipped to their customers. Auloma process monitoring and quality management enable to defects detection, parts traceability and data analysis transformed in actionable information to reduce scrap cost and maximize yield.
In the market are available many Force vs Distance monitoring system used to control the servopress applications, but anyone is comparable at the combination price, performances and functionality of APM. APM further the typical square force off set limits to control the waveform (Force vs Distance) can organize the force limits as an envelope to wrapping the complete waveform to analyse any points and capture any defects. This accurate control is the key to seeking whichever defects or process abnormalities.
Force VS Distance signature analysis provides the highest level of accuracy as well as repeatability and reproducibility because it measures the process against dedicated parameters of control developed in the software. Thanks to this net of control you can set up APM according your exigences and have the confidence that defects are being sought as they occur in manufacturing. Signatures provide a lot of data for univocal response. This data can be used for optimizing your tests and cycle speed to find the root cause of a defect
The servo press provide in the servo drive interfaces two analogue outputs. Encoder feedback and force sensor measures are analysed by the APM process monitoring software installed in the servo press controller. The controller has dedicated two analogue channel to execute the process analysis. In the channel (x) is possible set the ram position values and in the channel (y) is possible set the Force values. The waveform obtained by interpolation of two channels correspond at a mathematical model of the processed parts. The APM working for comparison and use a recorded masterpiece waveform to compare all processed parts. In APM process monitoring is possible on the masterpiece waveform set-up the off set force limits, this to create the force tolerance limits to discriminate the defected parts through waveform analysis. The APM process monitoring is available installed in the own servo drive PLC built-in that drive the Auloma servo press and the set up is possible through the APM ToolKit program. The response pass or fail (OK or NOK) of the processed part is noticed to main machine control ( operator console ) by a digital output or by Profinet, depending on APM model used.
The six sigma theory assert that the goal of a productive process is a value of 6 standard deviation within the upper limit and the lower limit around the centre. The centre consist in which values that represent the perfection of the quality process. In other words the maximum deviation of productive process shall be included in a gap of one twelfth in the entire specification wide. Often this rules isn't applied in strict manner. The six sigma is used as a methodology to reduce the production defects. This approach however result wrong today. A serious approach to six sigma methodology can help the industries to improve the quality standards and reducing the cost of waste products. Nowadays the technology offer an wide range of solution to monitoring the productive process and have measurement of process capability. This capacity is usual to create the quality benchmark to reach the 6 deviation. Auloma servo press thanks the built-in process monitoring can provide many information about the quality of the parts obtained by the press application. The data analysed by our process monitoring can be saved in remote by Ethernet connection in CSV format and processed in six sigma software applications.
The automotive industries needs of an high quality standards in all branches of the supply chain. All components produced might be manufactured according the ISO/TS 16949 standards. The procedures of ISO/TS 16949 help all players of the supply chain, Tier 0, Tier 1 and Tier 2 in implementation of benchmark capable to improve the quality day by day and seeking the abnormality of the productive processes. The standard ISO/TS 16949 was developed by IATF to encourage the enhancement of the supply chain and of its quality certification process and now it is impossible being a manufacturer of OEM's in automotive market without the assumption of this standards.
To improve constantly the process capability of OEM's manufactures is necessary provide many informations to the system of quality control . Quality manager to verify the benchmark process needs of many feedback from production's flow chart to have statistic and trends. Auloma Process Monitoring APM, further at its task of seeking defects and abnormalities in the processed parts, provide in CSV Format ( Comma Separated Values ) the values obtained for each part processed. Our process monitoring thanks to an Ethernet Interface can provide the process data to MRP , ERP ,Spread Sheet software or DB.