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Collision Damage Prevention and Analysis

Among the major concerns during machining is the possibility of a collision involving the machine spindle, tool or machine table. OMATIVE offers a solution that:

  • Maintains an ongoing record of event and machining parameters — information that is highly valuable for keeping shopfloor managers current about the status of machining operations.
  • Monitors and detects vibration on the spindle or the individual tool being used.
  • In cases of excessive vibration, a signal is sent to the machine to perform an emergency stop.

These steps result in totally avoiding collisions involving the spindle, tool and machine table, or in the rarer case of an actual collision, minimizing damage as much as possible.

Active collision damage prevention
OMATIVE's Vibration Detection and Prevention solution continuously monitors conditions involving the spindle, tool or machine table in order to avoid collisions. If such conditions are detected, the vibration detector stops the machine within one millisecond, preventing the massive damage resulting from such events.

In addition to preventing and avoiding significant damage to the machine tool and parts, the OMATIVE solution provides a reliable history of machining events. Machine tool manufacturers whose machines are still under warranty can investigate the log in order to uncover what or who is responsible for the collision that was prevented or minimized. This, naturally, has implications for coverage under the machine’s warranty, etc.

The data log enables:

  • Objective determination of actual causes of breakdowns
  • Collisions to be traced
  • Settling of damage claim disagreements between the machine tool builder and user
  • Resolution of inter‑departmental disputes regarding responsibility for damage caused

The log of events
The log of ongoing record of events and parameters is made on the OMATIVE Process Data Recorder (OMATIVE PDR) which runs on all CNCs. By recording the history of machine events and machining parameters, it is possible to trace the events leading up to dangerous overload conditions, machine crashes and part and tool damage.

Event and machining history can be viewed and examined by means of the OMATIVE Process Data Viewer (OMATIVE PDV) application, run on any PC.

The following data items are recorded by the OMATIVE PDR:

  • Axis motor torque and position
  • Spindle torque, speed and status (stopped, started)
  • Tool changes
  • Tool and axis offsets
  • NC Program name and its status (in progress, interrupted, stopped, etc.)
  • NC block
  • Operating mode (JOG, MDA, AUTO)
  • Selectable critical PLC variables
  • Alarms and PDR overloads


Recorded process data analysis screen  (click to enlarge)

Monitoring stops machining under dangerous conditions; collisions are avoided.  (click to enlarge)

The file viewer graphic shows vibration levels for a specific time period, including vibration peaks that set off alarms.  (click to enlarge)

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