SB-5523 ExactDress™ Grinding wheel balancers and laser sensors : Schmitt Europe Ltd.
Entry level system for grinding machine gap and crash control

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External AE Sensor

In-Spindle AE Sensor

Fluid AE Sensor

Mini AE Sensor

Balance Head AE Sensor

AE-1000

ExactDress™

AE Grinding Results

AE Dressing Results

 

exactdress

In the past, AE monitoring used adjustable linear limits, limited to fairly basic grinding wheel profiles and machine operations.
The ExactDress™ system from SBS enables precise monitoring of complex dressing operations for heavily profiled wheels. It does this by monitoring and analysing the AE (Acoustic Emission) signal they generate using Schmitt’s Process Curve firmware.
Up to 32 master, or good ‘Process Curves’ representing each dressing job can be stored in memory. The ExactDress™ system is unique in that it is ‘Self-Learning’; the teach function being instigated by an input from the grinding machine CNC/PLC. Changing grinding wheel properties and other varying machine parameters such as diamond life can be compensated using the Self-Learning facility.
Once production starts, each subsequent dress cycle is compared to this master Process Curve. The cycle is split into individual zones or time based segments. If any one of these zones is out of [a user pre-set] tolerance, then an output is given to the grinding machine control to highlight a problem has occurred.
The graphical output on the unit highlights which zones in a process are out of tolerance, showing the user the exact point of dressing where there is a problem.

Pic: traditional AE systems using 4 linear limits are ok for basic wheel profiles (LHS), but more complex profiles such as those for gear grinding are difficult to monitor using this method (RHS)

graph

Pic: the ExactDress™ firmware splits the raw (blue) AE signal into individual zones (green). The graphical area of each zone is compared to that of a master Process Curve. Less filtering and manipulation of the signal means quick setup and user friendly front end.

screen

Pic: screen shot of the ExactDress™ process in action. Individual zones are seen at the bottom of the screen. The saved master Process Curve for the job is seen behind. The red zones show the point in the process that is beyond a user pre-set tolerance.  Dark green illustrates zones that are within tolerance. The unit is able to ignore zones that are of no interest to the user. These are shown in blue.

View a movie of the ExactDress™

The video shows a rotary diamond dresser removing material from both sides of a profiled grinding wheel. A defect is intentionally scored into one side of the wheel. The different ExactDressTM zones can be seen in colour behind the raw AE signal output. Individual ‘good’ zones that are within the tolerance of the master profile are shown in green. Any defects in the dress that are deviating outside the allowed tolerance and highlighted in red. Any zones that are within the limit, but on the side of caution are highlighted in yellow colour.
The defect can be clearly seen, and an output is given to the CNC to highlight this. The dressing operation continues until the defect is cleaned out of the wheel.
The ExactDressTM card uses a unique method to generate the Process Curve. The firmware calculates the graphical area of each zone under the raw AE signal. No filtering of the signal is required, giving fast response time, easy user setup and front end.
The ExactDressTM system can be supplied as an additional card SB-5523 for a balancing system, or as a standalone system for any OD or ID grinding machine. Schmitt’s current range of external, internal and fluid AE sensors are compatible with the system.

 

 


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ExactDress™ equipment overview

 
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