Why Use Precision Sensors in Automated Lathe Processing?

Lathes have made remarkable strides in manufacturing by allowing the high-speed and repetitive manufacturing of intricate machine components. What's more fascinating is how further advancements in automation can improve the array of possibilities these machines have. Precision sensors integrated into machines can unlock the machines’ full potential. At FSCW Sensor, we focus on developing high accuracy sensors and enhancing the performance, reliability, and efficiency of automated lathes. In this piece, we aim to articulate the precise importance of these sensors and how they can help improve your manufacturing processes.

Why Precision Sensors Are Important In Automated Lathes Processing

Our sensors have the capability to track heat levels, ensuring that neither the device nor the workpiece gets damaged, so no unnecessary alterations are made. If overheating seems to be an issue, these integrated sensors can track and report on the issue, allowing for maintenance to be performed. In this case, temperature sensors do all the work. We also have displacement sensors integrated, measuring the tool in real-time and ensuring the accuracy of cuts made, so it is more than just an educated guess, cuts are made. Automated lathes do not have the capacity to maintain quality and consistency without these sensors.

Improving Quality and Accuracy

Failure in any device in aerospace , automotive and medical device industry can occur with the slightest alteration. Our advanced laser measurement units and capacitive sensors are capable of pinpoint accurate measurement of every component (micron precision. Each component touches very tight tolerances.) capable of dimensioning and surface finish corrections within each processing stage, thus limiting scrapping and improving product quality. Quality control like this is essential for any manufacturers looking to obtain certifications, for example, ISO 9001.

Less Manual Oversight

Using our integrated sensor systems, advanced sensors on devices like lathes can perform autonomous functions even with limited human interaction. Tools are aimed to be critical elements that prompt autonomous systems to change their operational state. A automated state can preset when Tool break, or when a material that can be used on the lathe is considered defective. This can not only make the system reduce the tools used but can also reduce the cost associated with manual inspections. Take for example, Tool condition monitoring sensors which can be used in a system to predict if a tool needs to be replaced in the near future. This later saves a lot of time in tool servicing.

Adaptive Machining Implementation

Today's manufacturing often needs modifications to parts that come in small batches. This means that lathes will have to quickly gear up to different activities. How do we do this? With Adaptive Machining made possible through approach data provided by advanced sensors. Our pressure and force sensors do this by adjusting the cutting structures according to material hardness so that all workloads are uniformly achieved. Such flexibility is extremely important for those industries that are adopting the innovations of Industry 4.0.

Also Important is the Investment and ROI

Although precision sensors are one of the expenditures made by a company in the short term, the amount saved in the long term is immense. Our sensors help, in many ways, lower operational costs by reducing costly breakdowns, minimizing errors and lowering waste. Moreover, the long lost data that is collected by these sensors help in the analysis and improvement of many processes which adds to the savings. At FSCW, we provide sensors which are durable and reliable that ensure a high ROI, designed to withstand the harshest industrial environments.

As noted, a huge part of the implementation of adaptive lathes hinges on the use of precision sensors. At FSCW, we work to offer the best precision sensors for which the company will always have a competitive edge. They are able to increase the accuracy and lower maintenance costs for the company.

FAQs

Which sensors are most important for automated lathes?

Displacement, temperature, and vibration sensors are important. Displacement monitors the lathes for dimensional accuracy. The temperature sensors help prevent the lathes from overheating, and the vibration sensors warn of tool wear, tool misalignment, and tool misalignment.

In which three ways do precision sensors lower operational costs?

They predict and counterbalance errors in real-time which lowers downtime, optimizes machining parameters which lowers tool wear, and lower scrap.

Is it possible to install precision sensors on older models of lathes?

Yes. Many of our sensors are developed for retrofitting of legacy systems. We do however, warn that it depends on the architecture of the control system of the lathe.