The precise detection and measurement of chipping, often in the tenths of a millimeter range, requires high-resolution measuring methods. In addition, the variety of tool shapes and sizes makes it difficult to develop a universally applicable inspection system.
Automation and efficiencyManual inspection by machine operators is time-consuming, error-prone and not suitable for high production volumes. The subjective assessment of wear can also lead to inconsistencies.
Imaging and data acquisitionRound and reflective tool surfaces make imaging difficult and require special lighting techniques. Capturing accurate 3D data under these conditions is a challenge.
The automated analysis of tool wear is a decisive factor for quality assurance and increasing efficiency in the modern manufacturing industry. Especially for indexable inserts for milling machines or lathes, precise monitoring of wear is essential to avoid production downtime, optimize tool life and ensure product quality.
Overcoming Inspection Challenges: The Limits of Conventional MethodsConventional inspection methods, such as manual checks by machine operators or semi-automatic checks at specified intervals, are often time-consuming, error-prone and lead to production interruptions. In addition, the diverse shapes and sizes of the tools and their reflective surfaces pose a challenge for imaging.
LightfieldLAB: Innovative 3D Imaging for Reliable Wear MonitoringThe lightfieldLAB system offers an innovative solution to these challenges. The use of high-resolution 3D imaging and precise measurement algorithms enables automated and reliable analysis of tool wear. This ensures permanent and reliable process monitoring and full traceability.
The holder is designed to enable the indexable inserts to be picked up quickly and easily. Manual operation of the holder allows flexible adaptation to different tool types and sizes.
Highly innovative sensor technologyOur Light Field Sensor HighRes with the highest resolution (with two achromats) provides precise image data. An additional polarization filter and highly diffuse light reduce reflections and also improve image quality.
3D analysisPrecise 3D analysis is made possible by special calibration and depth calculation components. These components ensure an accurate and measurable 3D reconstruction of the inserts, which is essential for defect detection.
Comprehensive evaluationTo ensure automatic measurement, our evaluation algorithm fits the calculated point clouds into optimal geometries and measures deviations. This data is automatically compared with predefined specifications.
UIsOur standard lightfieldLAB GUI includes calibration, depth calculation, live playback of kaleidoscopic imagery and the display of depth maps and point clouds. In addition, the GUI offers the marking of defects and display of measurement points in the analysis of tool wear.
The system enables precise and reliable detection of chipping and other signs of wear. This minimizes the risk of processing errors and ensures high product quality.
Automated measurement enables accurate verification of tool geometry without the need for manual interaction. This reduces the risk of errors due to human factors.
The predictive maintenance option enables predictive maintenance of tools. This reduces downtime and production costs.
The complete documentation of wear data enables easy traceability and process optimization. This supports compliance with quality standards and legal requirements.
Precise tool monitoring reduces scrap, resulting in significant time, material, and cost savings.
The user-friendly GUI enables intuitive visualization of defects, even the smallest imperfections. This facilitates fast and efficient verification of inspection results.
The automation of tool wear analysis reduces personnel costs and speeds up the inspection process.
Automated and precise tool wear analysis increases process reliability and improves product quality.
The possibility of predictive maintenance and the reduction of rejects lead to significant cost savings.
By precisely monitoring tool wear, tool usage can be optimized and tool life extended
