P3SE - NEW ELECTRONIC MONITORING SYSTEM FOR PROCESS CONTROL ON GRINDERS

Marposs has introduced a new apparatus for use in grinding machines monitoring and control applications.

The new Marposs P3SE utilizes inputs from various acoustic emission sensors to provide machine analysis and feedback for machine control.

AE sensors detect ultrasonic sound waves emitted when the grinding wheel contacts a part or the dressing wheel and send that information to the process control unit. Monitoring the sound waves and comparing them with reference values allows operators to control the grinding and dressing processes.

The P3SE is a new generation technology of the proven Marposs E20N "gap and crash eliminator" which has been successfully applied to many grinding machines for purposes of crash avoidance and to reduce "air cutting" time for optimization of grinding cycle times.

The new P3SE generates noise measurement controls from one or two acoustic emission sensors, to produce a "footprint" of the machine, providing an useful tool for force monitoring applications on grinding machines. Variations in acoustic emission indicate changes in cutting forces, which can then be modified. The P3SE essentially quantifies characteristics of the grinder which can be used in evaluating changes such as different grinding wheel materials or different operating parameters.

The new P3SE has already been used successfully for touch dressing of costly CBN grinding wheels used in high frequency external and internal grinding. In monitoring of dressing operations, a varying acoustic response when the dressing disk touches the wheel signifies irregularities on the wheel surface. Marposs P3SE and AE sensor system can detect variations of less 0.5μm on the surface of the wheel. After the disk dresses the wheel, a steady acoustic signature signifies the wheel is uniform and ready to grind.

The high efficiency and performance of Marposs P3SE is attributed to the wide frequency range covered by the unit (up to 1000 kHz) and the system's self-learning ability to acquire background noise level prior to dressing.