The torques of all axes and spindles involved in a machining operation are recorded via separate monitoring channels. A special, adaptive algorithm eliminates static weight and friction forces as well as dynamic acceleration forces, so that the process signal only represents the external forces resulting from the machining process. This principle allows comprehensive monitoring of the load conditions within the machine. During drilling or milling, a worn tool can generate enormous reaction forces on individual axes. Tool breakages or breakages of cutting inserts during turning affect the X, Y or Z-axis force in a specific way.

WFL iControl is fully integrated in the control interface. All relevant signals are shown on the display. Collision monitoring is active right after the machine is switched on. It responds to overloads on individual or several machine axes within just a few milliseconds. This essential monitoring is always active and protecting the machine, without the need for any special programming or operation, including when new NC programs are being run-in.

Signal sources
WFL iControl responds to the drive torques of the NC axes and spindles and also to signals from external sensors which are responsible for vibration, pressure, flow and temperature.

Signal evaluation
The process signals are evaluated according to a range of criteria. The settings can be customised, which means the available monitoring modes for the process signals can be freely combined during the individual machining operations. Collision monitoring, process monitoring and tool wear monitoring are used for evaluation.
• Collision limit
• Red limit
• Adaptive limits
• Dynamic limit
• Continuous limit
• Yellow limit
• Energy limits

Data recording
New functions also provide data recording by means of a blackbox and process recording function. If the collision limit is exceeded, a blackbox log file is generated. The target position, the actual speed, the current drive torque and the process signal in the interpolation cycle are logged in this file for all NC axes and spindles approximately 1 second before and after the collision alarm. A long-time data recording function can also be activated in the NC program at any time, so that the average, minimum and maximum values are recorded in a process log file at regular time intervals for each process signal.

WFL iControl allows users to develop a feel for the technological potential of the machine and tool. As a result, maximum safety and protection are guaranteed for the machine, tool and workpiece. In aviation in particular, this data is needed when special machining operations are performed. In these cases, the data has to be recorded. The logs provide subsequent verification that no notable incidents occurred in relation to process forces or coolant supply.

ADVANTAGES:
• Greater process reliability thanks to continuous monitoring of machining operations
• Protects the machine against damage
• Increased productivity and workpiece quality
• Tool cost savings and better utilisation of the tool life due to wear monitoring
• Better utilisation of the machine as process signals are shown on the display
• Integration of sensored tools
• Maximum sensitivity thanks to teach-in technology
• Option to perform monitoring without teach-in cut
• Optimum monitoring of machining processes with different cutting depths thanks to adaptive limits
• Option for early detection of machine wear