CNC spindles are a vital part of your machine shop operation, which is why keeping them running in top shape should always be a priority. Recognizing this, GMN has incorporated recent innovations in electronic spindle monitoring, making it possible to examine the performance of your spindles more closely. The IDEA-4S spindle monitoring system allows you to assess spindle performance in real time. Here’s how it works.

The IDEA-4S (Integrated Data Evaluation and Acquisition for Spindles) from GMN includes compact spindle sensors and a central control unit, accompanied by easy-to-use software. The system collects, processes, and stores information on the most vital functions of your CNC spindle. At a glance, you can see current and past spindle performance and potential problems, often long before they are apparent. Areas monitored include:

More importantly, these information points are continuously monitored, collected, and stored in a database. Spindle operators, production engineers, and management can use this data to better understand performance and examine spindle operation history. You will receive a detailed analysis of your spindle, which will include:

• Current status
• Usage history
• Usage statistics
• Spindle motor monitoring
• Histogram information to track the operating time in specific value ranges

There are several reasons why it is imperative that you employ a spindle monitoring system like IDEA-4S in your CNC operation:

CNC spindles represent a sizeable financial stake in your business. Properly monitored and maintained, a CNC spindle should serve you for an extended period before requiring substantial repairs or replacement. Spindle monitoring allows you to detect potential issues before they become production problems.

Studies have shown that companies can prevent 70% to 75% of breakdowns by practicing predictive maintenance, which involves monitoring systems prone to wear and failure. In the case of spindles, this includes cooling issues and tool clamping problems. A spindle monitoring system allows you to foresee these issues and avoid much bigger repair bills and costly downtime.

The critical detail spindle operators want to know is how their specific applications and usage affect the health of their spindles. Every CNC operation is different. How will heavy cutting, ultra-hard materials, or 24/7 operation make a difference in wear and maintenance needs? It will vary considerably from your CNC spindle colleague across the street specializing in light-duty projects. A spindle monitoring system can show exactly how the spindle performs in your workplace’s unique conditions, removing any room for guesswork.

When spindles go down, production stops, not only at the CNC machine center but often in upstream and downstream procedures in your plant or for other production partners and even customers. Spindle monitoring systems can usually detect minor issues that are warning signs of significant problems if left unattended. Knowing these issues exist allows you to schedule planned maintenance.

The IDEA-4S spindle monitoring system creates a record of your spindle performance and usage. When you send your spindle in for repair or maintenance, you also can send the record as an electronic data file. This allows the spindle repair technician to review the performance history of your spindle and determine maintenance issues and causes of malfunctions.

CNC spindles are precision machines. Undetected problems in your spindle result in poor performance, rejected products, missed deliveries, and a blemish on your company’s reputation. A monitoring system helps avoid any botched jobs for greater product integrity and customer satisfaction.

GMN USA uses IO-link technology to monitor spindle conditions. IO-Link (IO = Input/output technology) is a standard protocol for communicating between devices in an industrial setting. You get bidirectional data exchange between the master device, actuators, and sensors throughout your spindle assembly. IO-link is one of the principal technologies of the Industrial Internet of Things (IIOT) and is used worldwide (IEC 61131-9).

Monitored areas of your spindle include:

• 5 analog inputs for PT 100 temperature sensors
• 3 digital inputs for position sensors
• 1 analog input for a NAMUR speed sensor
• 1 internal 3-axis vibration sensor

The spindle sensors of the IDEA-4S provide statistical values, including minimum and maximum values, alarm, and fault status. You can link the output to your company computer network or, as indicated earlier, your IIOT. You always have a picture of your current spindle condition and usage history.

Initially developed for GMN spindles, the IDEA-4S spindle monitoring system now operates with all spindle brands. Variations of the system include:

• Basic. Providing the vibration signal without connected external sensors. It also includes nameplates and application data.
• Standard. Includes temperature and speed measurement.
• Advanced. Additional sensor options are available, such as an MSU sensor system to connect a release unit.

The experts at GMN developed the IDEA-4S spindle monitoring system based on their industry experience, of more than 100 years, and the need among industrial CNC spindle operators to better address spindle health. GMN USA staff are also experts in spindle repair and maintenance. We use quality components, creativity to produce special solutions for your needs, and provide expert, on-site spindle repair and maintenance.

Contact GMN USA today to find the right solution for your spindle monitoring needs.