w w w . d i g i t a l w a y g r o u p . c o m

Machine Tool protection and condition monitoring SafePilote

Protect your machine

and tooling

Minimize damage

resulting from collisions

Monitor and analyze your

machine behavior

w w w . d i g i t a l w a y g r o u p . c o m

Machine Tool protection and condition monitoring SafePilote

SafePilote is a 3-axis accelerometer sensor and

processor specially designed and built in Digital Way’s lab to provide you with the most effective means for protecting your machines against damage resulting from a crash or a collision. Mounted on your machine’s spindle, this powerful system also allows you to record vibration data associated with the conditions of machine use or with tooling quality.

Vibration monitoring is a key strategy to ensure the quality of your production, to check your tooling, and your machine components. This is also the fastest way to detect a collision and stop your machine quickly enough to prevent damage and downtime. Consequences of a crash during a machining operation are generally catastrophic: - Broken Part or Tool-holder, - Damaged spindle,

- Need to re-do all mechanical set-up, - Long downtime and production stoppages.

Why monitor vibrations?

The graph to the right shows the benefits of using the SafePilote system when a crash occurs on a machine. When a machine stop is decided by an over-current alarm on an axis movement, it’s often too late to avoid large damages to the spindle / tool / part fixture, leading to long downtimes and increasing your manufacturing costs. Of course, the SafePilote will not prevent the crash, but its extremely fast reaction time will allow a much faster machine stop and thus a drastic reduction in the repair costs.

Minimizing crash damage

Minimize crash damage by reacting fast to an impact and excessive vibration that involves spindles and/or part fixtures.

Machine Tool

Velocity

Time to

Machine Tool

stop

The SafePilote

Advantage

Money

Machine-Tool Axis

Over-current Alarm SafePilote

Alarm

Once installed on the machine, SafePilote quickly detects a crash and immediately stops axis motion.

Reduce cost How ?

Small, easy to install and adjust, SafePilote can protect machine tools, industrial robots, gantry systems, and industrial equipment.

On many applications Why ?

To minimize consequences of a crash and to reduce the repair costs.

SafePilote system What for ?

w w w . d i g i t a l w a y g r o u p . c o m

Machine Tool protection and condition monitoring SafePilote

SafePilote can be successfully applied on most kinds of machines: Machining centers, turning centers, grinding machines. It can be used only for machine protection, but it can also provide useful information about machine and tooling health.

The SafePilote system may be used on any type of machine tool. It may also be used on many robotic applications (palletizer, drilling, deburring, or welding robots) and material handling machines such as gantries.

SafePilote is available in several models, depending upon your needs and machine specifications. It can be used in « stand-alone » versions or as an addition to the Wattpilote to create the most complete monitoring solution for your machines and your tools.

Most important:

an industrial sensor Encapsulated in an M12 housing, the 3-axis acceleration sensor was designed to be a real industrial product. It is durable, compact, easy to install, and it has a quick-disconnect cable. In order not to be disturbed by the environment, the sensor output is digital: no need to take special precautions, the sensor cable can be mixed in the cable carrier system with the power supply cables for the spindle.

Adaptable to

all types of machining

Convenient installation

in the electrical cabinet The signal processing box is mounted in the machine tool electrical

cabinet. It connects to the PLC or machine control via a small number of discrete I/O. The 3-axis digital accelerometer is mounted on the spindle or part fixture. A quick-disconnect cable is between the processor and the accelerometer.

For each type of machine,

one SafePilote solution

Transfer line, Robot

SafePilote Extand

Machining centers, turning centers, grinding machines

SafePilote Premium

Machine tool, Robot, Gantry

SafePilote Access

MicroMon

One touch set-up system The optional MicroMon graphical HMI display allows fast and easy

process limit changes when production lot sizes are small: It's just necessary to activate one touch before the first part is machined and Micromon automatically analyzes vibration and adjusts parameters.

Successfully applied on most kinds of machines

No need to be a vibration expert to handle this system. Its simple interface has been specially developed to make it accessible to anybody, even without any knowledge about vibration sensing. Easy to install and set-up achieved with only a few clicks.

Easy to use

Keep an eye on the spindle condition by checking vibration levels in 3 different axes. Its very high sensitivity will also give you the ability to detect out-of-balance problems with your high speed tooling.

Check Spindle health

Excessive vibrations during machining are one of the main sources for degrading the quality of your production. This system will help you keep your machine working in good condition. Its very high sensitivity will also give you the ability to detect out-of-balance problems with your high speed tooling.

Ensure quality

This system will act as a true “black box” that will allow you to track all unexpected events occurring during the use of the machine. Each alarm will be stored in the system’s memory with the corresponding shock and vibration curve.

Events record

The vibrations in the X, Y, and Z directions and the RMS vibration are shown along the top of the screen. The Shock plot shows fast-response impacts and the Vibration plot (actually RMS vibration) shows the time-averaged vibration level. With a reaction time of around 0.5 milliseconds, the SafePilote will effectively reduce the damage resulting from unexpected events during your machining process.

Limit damage

Machine Tool protection and condition monitoring

Electrical cabinet

SP-A0

Machine Tool

PLC

WE-M01

CNC

Machine control panel

SW-A05

WE-M10

RJ-P01

WL-E05

SP-Visu-C

Laptop PC

WE-M10

AG-03M

CA-M15

24V DC 3A

PLC

NC Interruption

Spindle

Single-spindle machine tool with numeric control

SafePilote

Collision

Excess Vibration

Chatter

Balance

Machine analysis

Spindle condition

Technology 3-axis digital accelerometer ± 16 g

Sensitivity 4mg

Maximum shock 10,000 g shock survival

Sampling rate 3200 Hz

Ambient temperature -20 ... 85°C

Dimensions L 45 mm, Diam. M12

Protection rating IP 67

Weight 15 gram

Technical characteristics Sensor

Access

Extand

Premium

Processor Technical characteristics

Power supply 24 VDC ± 10 % , 200 mA

Number of different process 1 120 120

Reaction speed 0.5 millisecond

Collision control x x x

Vibration control x x x

Balancing control x x x

Clamping control -- x x

Saved events last 1 500 000

Saved events curves last 10 000

FFT analysis capabilities x x x

Optional analog output available x -- --

PLC Interface 24 VDC 24 VDC Profibus

Fast Inputs

24 VDC type II, 15 mA

Fast Outputs Work contact static relay 24VDC

Supervision Interface Ethernet - 10/100 Base Tx

Communication protocol with sensor Numeric (CAN Network)

Maximum length of sensor cable 80 meters

SP-A0 SP-E0 SP-PP

SafePilote reference

Part Nr. Access

Extand

Premium

Sensor

AG-03M

Number of different process 120 (15 with WattPilote Transfer)

Reaction speed 0.5 millisecond

Saved events last 1 500 000

Saved events curves last 10 000

Fast Inputs

24 VDC type II, 15 mA

Fast Outputs Work contact static relay 24VDC

Communication protocol with sensor Numeric (CAN Network)

Maximum length of sensor cable 80 meters

Technical characteristics

Processor

Tool Wear

Tool breakage

Insert breakage

Missing tool

Double machining

Tool/Part contact

WattPilote

SafePilote

Collision

Excess Vibration

Chatter

Balance

Machine analysis

Spindle condition

Technology 3-axis digital accelerometer

Measurement range ± 16 g

Sensitivity 4mg

Maximum shock 10,000 g shock survival

Sampling rate 3200 Hz

Ambient temperature -20 ... 85°C

Dimensions L 45 mm, Diam. M12

Protection rating IP 67

Weight 15 gram

Technical characteristics Sensor

Example

WP-CN-S032+SP : WattPilote Single Evolution – 32KW three phased spindle – ProfiNet interface – SafePilote option

WP-AN-S016+ SP : WattPilote Contact Evolution – 32KW three phased spindle – ProfiNet interface – SafePilote option WP-LN-S032/A008+SP : WattPilote Turning Evolution - 32 kW Main Spindle / 12 A axis – ProfiNet interface

Example

WP-DN-S032+SP2: WattPilote Dual Evolution – 32KW three phased spindle – ProfiNet interface – 2 channels SafePilote WP-QN-S016+SP1: WattPilote Quad Evolution – 16KW three phased spindle – ProfiNet interface - 1 channel SafePilote

Dual – Triple - Quad

Reference WattPilote + SP 0

0 : Number of SafePilote channel SP : SafePilote Option

Single - Transfer - Contact - Turning

SP : SafePilote Option

Reference WattPilote + SP

WattPilote Evolution reference

Part Nr.

Electrical cabinet

WP-CN-S032+SP

Machine Tool

PLC

Frequency converter

WE-M01

CNC

Machine control panel

SW-A05

WE-M10

RJ-P01

WL-E05

WP-Visu-C

Laptop PC (Backup)

WE-M10 WE-M01

AG-03M

CA-M15

24V DC 3A

PLC

NC Interruption

Spindle

Single-spindle machine tool with numeric control

WattPilote & SafePilote – The best monitoring

Access

Exta

nd

Pre

miu

m

Em

bed

ded

Ma

ch

ine

s

Automatic boring machines with single tools

Boring / deep hole drilling machines or multi-spindle machines

Transfer machines and multi-station special machines

Fully automatic milling machines

Single-spindle machining centers and special machines

Double-spindle machining centers and special machines

Three-spindle machining centers and special machines

Four-spindle machining centers and special machines

Fully automatic turning machines and turning centers

Special turning machines

Surface, cylindrical, internal, and centerless grinding machines

Industrial robots

Machining robots

Gantries

Ma

ch

inin

g /

Ap

plic

ati

on

s

Boring or deep hole drilling with single tools

Boring, drilling or tapping using a multi-spindle head

Drilling with a boring bar or a tool with multiple inserts

Machining with complex cutting tools

Boring with ¾ borer

Rough machining, machining of raw parts

Finishing milling

Turning / rough milling, turning work on a rough part

Finish turning work

Beam drilling (cycle optimization)

Crankshaft shaving

Gear cutting

Crash detection

: Optimal performance : Works under certain circumstances : Not recommended

Selection guide

w w w . d i g i t a l w a y g r o u p . c o m

Machine Tool protection and condition monitoring SafePilote

For each type of application, one SafePilote solution

Machining centers

Gantries

Industrial

robots

Improve machine

maintenance

Swiss type machines

Transfer lines

Successfully applied on most kinds of machines

Z X

Y

M12 x 1

3.50 mm

32.00 mm

48.00 mm

17

Z X

Y M12 x 1

Sensor mechanical dimensions

Top view

Left view

Processor left view

80.00 mm

105.0

0 m

m

Processor front view

47.50 mm 66.50 mm

Sensor

access

100M

L

ink

Dig

ital W

ay

Sa

fe

Pilo

te

Machine tool crash protection

PWR

GND

WFR

BAL

ACQ

SLW

ALR

COM

MON RUN

ALR SLW

Sensor

100M

L

ink

D

igit

al W

ay

Sa

fe

Pilo

te

Machine tool crash protection and condition monitoring

DT1

DT2

DT4

DT5

DT6

DT7

CPL

GND

DT3

PWR

GND

WFR

BAL

ACQ

SLW

ALR

COM

MON RUN

ALR SLW

DT2 DT1

2 DT4 DT3

DT6 DT5

CPL

DT7

extand

66.50 mm

PWR

GND

WFR

BAL

ACQ

SLW

ALR

COM

100M

L

ink

Sensor

Dig

ital W

ay

Sa

fe

Pilo

te

premium

Machine tool crash protection and condition monitoring

MON RUN

ALR SLW

ERR DIA

F R A N C E Digital Way SAS - Saint Etienne Tél.: +33 (0)4 77 74 92 50 contact@digitalwaygroup.com

U N I T E D S T A T E S Digital Way Inc. – Michigan Tel.: +1-805-433-2820 john.cosic@digitalwaygroup.com

D E U T S C H L A N D Digital Way - Frankfurt / Main Tel.: +49 069 9621 76 64 joachim@digitalway.fr

I T A L I A Angiolini Franco – Milano Tel.: +39 342 143 2840 angiolini.f@gmail.com

E S P A Ñ A Danffor – Eibar Tel.: +34 943 820 464 danffor@danffor.com Maquina Center – Barcelona Tel.: +34 93 697 2726 sagullo@maqcenter.es