The challenge:
Fine machining processes such as honing or grinding are used in transmission manufacturing. These methods can cause problems, such as periodic geometry deviations like microwaviness. This is caused by vibrations during the manufacturing process due to relative movements between the tool and the workpiece. Microwaviness often lead to noise problems with gears. If these are not detected until the end-of-line test, the entire transmission would have to be dismantled again in case of doubt. Another problem with honing is honing ring breakage. If this event is not noticed in time, fragments of the broken honing ring can cause consequential damage in the machine. In addition, defective parts would remain in the production process. In the practice of machining, user errors are also possible. Clamping errors can occur during the dressing process – imbalances when the spindle starts up are the result.
The solution
The goal is to control parts in the machine across all work steps and manufacturing processes, in real time during production. Software solutions such as autinityVC from Schaeffler Digital Solutions do just that: autinityVC is a vibration analysis software that evaluates data from vibration sensors during ongoing production, compares it with stored reference values, and reacts immediately in the event of deviations by accessing the machine controller via an interface. For example, a tool breakage would cause a sudden peak in vibration, so autinityVC’s shock monitoring system would sound an alarm, trigger a notification, and stop the machine. The software also automatically detects components that are to be considered acoustically critical due to pronounced microwaviness. The affected workpiece is rejected or marked for tracking.
The result
The quality of parts and material is determined in real time during production. Defective parts can be rejected without passing through further production steps. Using the example of process monitoring on honing machines, considerable repair costs per damage case can be saved by using autinityVC. In the event of any production errors or tool breakage, autinityVC stops the machine and initiates the ejection of the affected parts. The subsequent workpieces remain intact – scrap is reduced. The rapid detection of deviations in the production process prevents consequential damage and thus long, unplanned downtimes. autinityVC offers an analysis tool that can be used to evaluate and improve production processes – thereby optimizing cycle time. Furthermore, tool wear is detected and the tool can be replaced in time. autinityVC can also be used as a data source for traceability, as it allows parts to be identified downstream.
