Presetting for tool-management systems.Presetting for tool-management systems
A basic tool-management system should supply proper tools and tool data to appropriate metalworking machines in a timely manner. If we accept this definition, then a tool-preset machine will be the basis of a good system.
Such a machine, at the very least, must provide properly set tooling and accurate tool data to the machines within the tool-management system. In this way, even the simplest presetter enables users to reduce downtime The time during which a computer is not functioning due to hardware, operating system or application program failure. while improving quality.
To assist in selection and assembly of the proper size and type of tooling, more advanced preset preset Cardiac pacing A parameter of a pacemaker that is programmed permanently when manufactured machines employ CRTs to display descriptions of tool components, crib locations, tool numbers, and programmed tool lengths and diameters. The information can be provided on site at the preset area through hand-carried notes, but it's safer to use floppy disks or a hardwire link to the manufacturing system's host computer.
Once the components are assembled into a complete tool, the preset operator can begin inspection and measuring on the preset machine. The presetter should simulate the tool-holding arrangement of the machine-tool itself, so tools can be examined with consistency.
Transducers and projectors
Vertical and horizontal tool-preset machines should be equipped with measuring systems featuring linear transducers and either a digital readout (1) A small display device that typically shows only a few digits or a couple of lines of data.
(2) Any display screen or panel. (DRO DRO Digital Readout
DRO Detention and Removal Operations (US Immigration and Customs Enforcement)
DRO Domestic Relations Order
DRO Department of Radiation Oncology
DRO Dielectric Resonator Oscillator
DRO Destructive Read Out ) or a tool-presetting software program. The program can store a series of reference-plane coordinates and tool dimensions, and can direct the machine to automatically position the preset axes and turret magazine under a CNC (Computerized Numerical Control) See numerical control.
CNC - Collaborative Networked Communication mode. In addition, the measurement system should gage the distance from the spindle spindle: see spinning.
A rotating shaft in a disk drive. In a fixed disk, the platters are attached to the spindle. In a removable disk, the spindle remains in the drive. Laptops use spindle designations to indicate the number of built-in drives. or adapter reference points to the tool point in increments of 0.0001".
An optical profile projector on the tool-preset machine magnifies the tool point to allow measurement of tool length and diameter, and allows the operator to inspect the tool point for runout run·out
1. The act or an instance of fleeing so as to evade undesirable consequences.
2. The area where one curved surface merges with another: a snowy runout at the bottom of the ski slope. , alignment of cutting edges, and proper nose radii ra·di·i
A plural of radius.
a plural of radius . Additionally, the profile projector guarantees that tool diameters are measured at their maximum diameter and permits the operator to view changes in tool length and diameter during adjustment. The projector can be equipped with a charged-coupled device or photoelectric Converting photons into electrons. When light is beamed onto a metal, electrons are released from its atoms. The higher the light frequency, the more electron energy released. Photonic sensors of all kinds work on this principle. They sense light and cause an electric current to flow. diodes that provide electronic noncontact measurement of tool length and diameter.
After presetting the tool, the operator can put a label on it for identification. These labels contain tool number, tool dimensions, and other characteristics.
Next, preset tools should be grouped according to according to
1. As stated or indicated by; on the authority of: according to historians.
2. In keeping with: according to instructions.
3. an intended operation for a targeted machine tool and transported directly to that machine. Then, the system should transmit data on tool length, diameter, and offsets to the machine by hardcopy listing, tool labels (man readable or bar codes), punch tape punch tape
A paper ribbon in which holes representing data to be processed by a computer are punched. , or direct link through an external computer.
Once the tooling has served its intended purpose, or has attained its use life, it should go back to the toolcrib preset area for dismantling, cleaning, resharpening, and preparation for recycling.
Developing a tool-presetting
Presetting can be defined as the act of providing a predetermined pre·de·ter·mine
v. pre·de·ter·mined, pre·de·ter·min·ing, pre·de·ter·mines
1. To determine, decide, or establish in advance: space relationship between the cutting edge (or edges) of a cutting tool in a reference plane (or planes). Simply stated, tool presetting means setting cutting tools to rough, semi-finish, or, in some cases, finish part dimensions on equipment designed exclusively for setting tools.
A tool-presetting system for complete tool management involves much more than setting tools to proper length and diameter. It should dispatch tool data in a format most acceptable to a particular facility. Because there are so many facilities that use tool-management systems, there are several alternatives available for transmitting tool data from the actual tool-presetting device to the machine tool.
At a beginning level (Level 1), a presetting machine can use a sophisticated DRO. On a higher level (Level 2), it could use an elaborate tool-setting software program to store and access tool data. Each level employs different stages of tool management, and these must be understood to select the correct presetting system.
Level 1 is composed of three stages of sophistication so·phis·ti·cate
v. so·phis·ti·cat·ed, so·phis·ti·cat·ing, so·phis·ti·cates
1. To cause to become less natural, especially to make less naive and more worldly.
2. , which you can implement separately or in conjunction with any other stage in this category. Stage 1 consists of a tool-preset machine and a DRO. The DRO should display actual length and diameter in inches and metric units--all selected by simple switches. This setup is enough to provide accurately measured tools on a consistent basis.
Stage 2 is comprised of a tool-preset machine, a DRO, and a printer that produces hardcopy labels to attach directly to the preset tool. The dimensional data dimensional data
see dimensional data. on these labels can eliminate human error in reading and recording tool information at the crib as well as the machine tool.
Stage 3 adds a one-way interface to an external computer. The computer then uses the preset data to create files containing tooling coordinates. This plan enables the preset machine and DRO to act as a simple gage and eliminate human error in reading and interpreting dimensional information.
Level 2 has eight stages of sophistication, which, again, you can implement separately or in conjunction with other stages. Stage 1 consists of a preset machine and an advanced tool-presetting software. The software program can store tool records and part lists and also produce detailed tool drawings based on tool dimensions measured by the preset machine. The programs also can determine actual and differential values, thereby eliminating manual calculations.
Stage 2 introduces floppy-disk drive to Stage 1, expanding the memory of the tool-presetting program.
Stage 3 adds a label printer to the setup to create labels with tool-identification number, length values, diameter dimensions, etc. It also produces bar-code labels for reliable data transfer.
Stage 4 enables the tool-preset machine and tool-presetting software to work together and produce a punched tape Punched tape or paper tape is a largely obsolete form of data storage, consisting of a long strip of paper in which holes are punched to store data. It was widely used during much of the twentieth century for teleprinter communication, and later as a storage medium for with tool offsets for any style of machine tool. It eliminates human error during tool-data entry into the machine control.
Stage 5 consists of a microchip (1) Another term for a microminiaturized integrated circuit (a "chip").
(2) To insert an RFID tag beneath the skin of an animal. It is expected that some day, humans will be microchipped. and read-write device embedded Inserted into. See embedded system. in the body of the tool being measured by the preset machine. The read-write unit reads the microchip and calculates the offsets before writing the updated data back to the microchip. This stage eliminates any visual misreading MISREADING, contracts. When a deed is read falsely to an illiterate or blind man, who is a party to it, such false reading amounts to a fraud, because the contract never had the assent of both parties. 5 Co. 19; 6 East, R. 309; Dane's Ab. c. 86, a, 3, Sec. 7; 2 John. R. 404; 12 John. R. of tool data by the human eye.
Stage 6 consists of a tool-preset machine, the software program, and an external computer interface that allows two-way communication Two-way communication is a form of transmission in which both parties involved transmit information. Common forms of two-way communication are:
Stage 7 provides a turnkey package. It uses a stand-alone IBM (International Business Machines Corporation, Armonk, NY, www.ibm.com) The world's largest computer company. IBM's product lines include the S/390 mainframes (zSeries), AS/400 midrange business systems (iSeries), RS/6000 workstations and servers (pSeries), Intel-based servers (xSeries) PC/XT PC/XT Personal Computer/Extended Technology (IBM) computer instead of the basic external computer used in Stage 6. This setup permits a self-contained tool-management-software package to communicate with the preset machine and to produce tool drawings, tool-assembly sheets, and setup sheets. The major advance of this stage is the formation of an elaborate tool-management system without the need for a large external computer.
Stage 8 adds a video camera to view the measured tool. The vision system calculates actual length and diameter of tools and eliminates the need for an optical profile projector, providing extremely accurate and reliable dimensional measurements.
The different levels and various stages of presetting systems are designed to meet individual needs within a tool-management system. Each progressing stage or combination of stages reduces the chance of human error while decreasing the time required for the machine tool to receive critical tool-characteristic information.
Automatic tool presetting
In addition to the various levels and stages of tool management that require some form of operator involvement, it is also possible to achieve a completely untended presetting station. For manless operation, a preset machine would have to automatically position the X and Y axes to a predetermined location. Also, it would require a tool-tracking device and a vision system to measure and inspect cutting edges.
Other equipment would include a robotic load and unload unit for positioning tools in preset-machine spindles and removing them upon inspection. Finally, an external computer would act as a communication link between all of the elements of the automatic tool-preset machine.
Total preset automation may be too elaborate for most users, but it illustrates the possibility of maximum efficiency in tool-management systems.
CNC machines as standalone units in manufacturing cells or in manufacturing systems are expensive to purchase and operate, but they offer high efficiency, great versatility, and other benefits that are universally recognized. However, these benefits are lost when the machine spindle is idle.
A tool presetting system can improve efficiency of a wide variety of standalone machine tools and NC machining centers. The presetting program can encompass practically all phases of tool preparation, which many times are performed somewhere in the manufacturing arena at the expense of productive machine time.
With emerging trends toward computer-aided manufacturing computer-aided manufacturing (CAM), a form of automation where computers communicate work instructions directly to the manufacturing machinery. The technology evolved from the numerically controlled machines of the 1950s, which were directed by a set of coded and flexible manufacturing systems Flexible manufacturing system
A factory or part of a factory made up of programmable machines and devices that can communicate with one another. , the role of the presetting machine takes on more importance. Without an effective overall tool-management system, even the most sophisticated manufacturing installation will fail to reach productivity goals.
The integration of the tooling-setup function on line with the machine-communication network is essential for proper use of a precision tool-presetting system. The direct cost benefits of good presetting mated with tool management include reduction of machine downtime, reduction of setup time, elimination of trial cuts, greater tool standardization, better tool-inventory control, and reduction of potential machining errors.
PHOTO : Operator prepares to set drill bits on a Variset vertical two-axis toolsetting gage. Graphic system displays tool layouts, dimensions, and special notes to toolsetting personnel. Photo courtesy Royal Design & Manufacturing Inc.
PHOTO : Tooling Systems Div (DeVlieg) offers all line of presetters including Model PSV-2550 vertical with precision rotary spindle, and Model PSH-3070 horizontal with pneumatic pneumatic /pneu·mat·ic/ (noo-mat´ik)
1. pertaining to air.
1. Of or relating to air or other gases.
2. clamping to relieve operator fatigue and ensure consistent tool positioning. TSD TSD Tay-Sachs disease. offers CATS(TM) Computer Aided Tool Setting software to link the preset machine to machine tools. It stores a variety of tool characteristics and ensures prompt tool placement, reduction of written tool reports, selection of alternative tools, and elimination of obsolete tools. Tool-management systems improve quality of all tools whether they need setting or not. A management system generally monitops every tool going through the "funnel," acting as a manager to keep track of the going and coming of all tools in and out of the crib.
PHOTO : The Firth firth or frith, Scottish term applied to an arm of the sea, usually an estuary or strait. For Firth of Clyde, see Clyde; for Firth of Forth, see Forth. Set(TM) digital presetter from Teled8ne Firth Sterling comes in three configurations: manual, with Soft Touch(TM) probe; visual, with camera-enhanced vision system; and computer enhanced, with special optics and software to create, store, and retrieve graphic colored tool overlays. Command Corp. International's tool holder presetter adjusts diameter at any height, length at any point on the diameter, length and diameter simultaneously, and tool runout.
PHOTO : DeVlieg (TSD) Model PSV-200 vertical preset ma hine has two-axis digital readout and 3" optical profile projector that magnifies tool point 20 times. No 50 tapered ta·per
1. A small or very slender candle.
2. A long wax-coated wick used to light candles or gas lamps.
3. A source of feeble light.
a. spindle locates and orients tools ranging to 18" length and 15" dia.
PHOTO : Operator sets inserts on milling cutter a fluted, sharp-edged rotary cutter for dressing surfaces, as of metal, of various shapes.
See also: Milling using Royal Design's Variset 2 HP Series horizontal two-axis toolsetting gage.