Prototype TOS Varnsdorf-2019 Machine tool management system

Horizontal boring machines (with a typical table size of 1000 mm and more) represent investment units worth several dozens of millions of CZK. They are used mainly for the production of large and complex parts, like components for automotive, processing, mining or petrochemical industries. The useful value of the machine can be increased by digitising some operations - from industrial communication with production control systems, through in-process control of machining and machine status during operation to the integration of additional devices that increase the accuracy, reliability and productivity of production on the machine.

The TOS Control machine management system creates a unified gateway to the world of digitisation and machine connectivity. TOS Control represents the basic machine system not only for the operator, but also for system integrators and software developers. TOS Control works closely with various types of control systems and provides a unified interface for control and further development. Additional basic information about TOS Control can be found, for example, in [1] and [2].

After the fundamental development and testing phase, TOS control was transferred to TOS VARNSDORF a.s., where it is currently integrated into all new machine tools delivered to customers around the world. TOS VARNSDORF a.s. and the Czech Technical University in Prague, Faculty of Mechanical Engineering continue to cooperate on the development of this system in terms of system maintenance, integration of other control systems and expansion of its functionality.

The main building block of TOS Control is represented by partial applications (application modules) that use the created communication and user interface. The default applications include the user environment of the CNC control system, a unified machine status screen, as well as documentation, a calendar, and also the display of information from the IP cameras.

Within TOS Control, special applications have already been developed and implemented, expanding the functionality of machines and facilitating their use. This includes, for example, the In-process Measurement application integrating the functionality of a machine tool and a coordinate measuring machine, including metrology software. Thanks to this application, production efficiency has significantly increased, as manufactured parts are automatically measured and corrected without the need for inter-operational transfer to coordinate measuring machines. A secondary consequence of deploying such a system is a significant reduction in the continuous production time, especially for large parts, and the elimination of inter-operational manipulation with large parts, which also contributes to the cost and energy efficiency of production.

Other developed and implemented applications include tools to visualise the physical characteristics of the machine with a direct link to the cutting process. Thanks to this, it is possible to eliminate problematic parts of the trajectory and thus increase production quality. TOS Control also enabled the development of an application for communication with the ERP system, where relevant work orders and operations are displayed directly on the machine control panel, including all related documents and NC programmes. This allows the operator to efficiently take over operations and report their completion directly from the machine.

In the area of diagnostics, TOS Control includes an application that monitors the spindle lifetime. The remaining lifetime of the main bearing is determined using machine learning tools based on the vibration level course and spindle accuracy. As a result, it is possible to better plan the spindle bearing service, make better use of machine components, and reduce the material intensity of machine operation (reducing the volume of consumable components).

Tools for increasing accuracy include an application for monitoring and compensation of thermal deformations, which was published in [3]. The TOS Control system also enables operation and process monitoring. Through the OPC-UA interface, TOS Control is connected to MES systems that publish overview reports on machine operation. From the process monitoring perspective, data is stored in a database, the conceptual design of which was published in [4].

TOS Control is implemented on the Siemens Sinumerik 840D sl and Heidenhain TNC640 control systems, which are among the most frequently used, especially on the European market. Since 2020, TOS control has become a standard part of all machines produced by TOS VARNSDORF a.s. and is implemented on dozens of machines at customers all over the world. Thanks to the TOS Control system, machines produced by TOS VARNSDORF a.s. are compatible with the requirements of Industry 4.0 and reach the communication and interaction level of the world's leading machine tool manufacturers. The TOS Control system has thus enables the use of TOS VARNSDORF a.s. machines even by customers with high requirements of the operation comfort (or unattended operation), extended machine functions and communication within the entire company, with a fundamental impact on improving the efficiency and productivity of production on machines equipped with this system. Typical users of TOS Varnsdorf machines with the TOS Control system are manufacturers of large complex products from all over the world. The machine management system contributes to improving the following goals of the Strategic Research Agenda for the field of mechanical engineering production technology: [o2] Quality; [o4] Reliability; [o5] Economy.

Thanks to its unique functions described above, the TOS Control machine management system has been supplied so far to more than 100 customers all over the world (EU countries; outside the EU countries, these include Peru, South Africa, Ukraine, Canada and others). For TOS Varnsdorf, this system is a key element of the digitalisation of machine functions for its integration into modern so-called digital factories. To continue the TOS control development, TOS VARNSDORF a.s. has built its own software department, which is closely connected with the Czech Technical University in Prague, Faculty of Mechanical Engineering. More to that, the system enables secondary business with advanced additional machine functions (additional measurement of part accuracy on the machine, analysis of residual spindle durability, etc.). Thanks to the implementation of the system, the company managed to obtain new orders based on the integrated unique technology and the company continued to keep and even slightly increase machine sales in some markets. At the same time, the system contributed to supporting the sales of the latest types of machines from the company's portfolio, which provides higher margins to the company. Thanks to a valid agreement on the financial shares, the sale of machines with the TOS Control system also has a financial effect for the Czech Technical University in Prague thanks to compensation for revenues from the applied intellectual property.

The TOS control system represents a powerful tool for expanding the useful properties of production machines and their effective use and brings machine manufacturers another opportunity to differentiate themselves from the competition. For CTU, FME, Ú12135, the development of such systems is one of the key activities, which allows the integration of partial developed technologies directly into production machines.

Articles:

1. Švéda, J.; Chládek, Š.; Hornych, T.; Kozlok, T.; Smolík, J. Increasing Machining Accuracy Based on CNC Machine Tool Correction Data by Using Ad Hoc Modification Machines. 2022, 10(5), 1-17. ISSN 2075-1702. DOI: 10.3390/machines10050288

2. Kolář, P.; Janota, M.; Švéda, J.; Kozlok, T. Method for Safe Experimental Testing of Machine Tool Usable Spindle Power. MM Science Journal. 2021, 2021 5167-5174. ISSN 1803-1269. DOI: 10.17973/MMSJ.2021_11_2021176

3. Mareš, M.; Horejš, O.; Straka, M.; Švéda, J.; Kozlok, T. An update of thermal error compensation model via on-machine measurement MM Science Journal. 2022, 2022(5), 6275-6282. ISSN 1803-1269. DOI: 10.17973/MMSJ.2022_12_2022150

4. Švéda, J.; Kolář, P.; Rytíř, M.; Fojtů, P.; Fiala, Š.; Chládek, Š.; Kozlok, T.; Machálka, M. Framework for milling process monitoring MM Science Journal. 2022, 2022(3), 5969-5978. ISSN 1803-1269. DOI: 10.17973/MMSJ.2022_10_2022123

In collaboration with:

Contact:

Ing. Matěj Sulitka, Ph.D.

Department of Production Machines and Equipment FME CTU in Prague

E-mail: matej.sulitka@fs.cvut.cz

Phone: +420 221 990 944