CNC Capabilities Brochure - Electrochem Solutions

WirelessSensingSolutionsfor CNCMachiningReal time. Real power. Real control.

Multi-Pallet SystemTwo-Pallet System

MORE PRESSURE ON YOUR PARTS.LESS PRESSURE ON YOU.Maintaining a specific hydraulic clamping pressurethroughout the machining process is critical for CNCoperations. If the pressure fluctuates, the consequenceof damaged equipment can significantly increasemaintenance costs, downtime, labor expenses, scrap,field failures and recalls – ultimately affecting profitability.At Electrochem, we provide complete systemsdesigned to proactively detect these problemsbefore they cost you valuable time and money.For over 30 years, Electrochem Solutions, Inc., a subsidiary of Greatbatch, Inc.,has been a leader in providing technology solutions for applications where failureis not an option. Steeped in the tradition of innovation, high quality and reliability,Electrochem possesses an in-depth understanding of customized battery powerand wireless sensing solutions for critical markets, and a legacy of providingthese solutions.Our complete wireless sensing systems include wireless sensors, base stations andsoftware that communicates with your machines, monitoring critical hydraulicpressures more frequently and accurately than ever before. These advancedsystems are designed to function in harsh industrial conditions without dangerouswires, providing early detection of potential pressure breaches and ensuring thatparts are held securely.Our goal is to help you:• Enable “lights out” manufacturing to increase automation• Remotely monitor actual pressure measurements(±1% full scale) on up to 127 pallets in real time• Reduce unnecessary labor costs• Avoid downtime and costly damage to equipment• Increase production time, profitability and customer satisfaction• Eliminate unsafe and impractical wires

ELECTROCHEM OFFERS BOTHTWO-PALLET AND MULTI-PALLETWIRELESS SENSING SYSTEMS.Two-Pallet SystemThis basic set-up – which includes one base stationand two wireless sensors – is ideal for a single machinewith two interchanging pallets. A standard Two-PalletSystem acts as a safety switch, helping an end user whoneeds to know and react if the clamping pressure fallsbelow the specified threshold; the user sets a specificlow pressure limit for pressure breach alerts via thetouch panel interface.Multi-Pallet SystemOur Multi-Pallet System is designed to easily monitorup to 127 interchangeable pallets. These pallets can bepaired with a single machine, or may be used amongdifferent machines (users can connect one wirelesssensor to multiple machines and base stations).The Multi-Pallet System also allows direct communicationto the machine’s controller. This system enables youto run “lights out.” When a wireless sensor reports apressure lower or higher than a preset value required toclamp a part, the base station can immediately displaythis condition to the operator and automatically stop themachining process, thereby preventing damage to theCNC machine, tombstone and operator.This system – which uses a “sleep mode” to optimizebattery life for inactive wireless sensors – is designed foran end user who requires the ability to easily configuremany parameters. For example, users can set a lowerand upper pressure threshold limit for each wirelesssensor to trigger pressure breach alerts.Features• Easy to install, all-in-one wireless pressure sensorand transmitter• Transmission range of up to 300 feet• Measurement ranges from 100 to 10,000 PSI• Accurate and reliable pressure readings,±1% full scale• Instant reporting of failure and initiates the machine’sresponse if PSI falls below the specified threshold• Designed to work in the rugged conditionsof a machine shop• Interfaces with machine controls viainternal relay (Two-Pallet System) ordigital I/O using DB25 connector(Multi-Pallet System)• Value-added touch panel display,with user-friendly functionality• Password protection function securesvariable pressure limits• Flexible fit on new and existing systems• Powered by one 3.9V AA primaryElectrochem batteryBenefits• Provides proactive, diagnostic monitoring andalerts throughout the machining process• Monitors hydraulic pressurization beforeand during machining• Reduces machine maintenanceDB25 Connector• Minimizes production downtime• Significantly decreases scrap• Lessens machine time spent on defective parts• Helps you produce high-quality end productsfor your customers

SEE FOR YOURSELF WHY ELECTROCHEMBEATS THE COMPETITION.ElectrochemCompetitionMaximum transmission distance 300 feet 40 feetUser interfaceEasy-to-use, advancedtouch panel displayTraditional 4-button interfacewith digital displayPressure adjustment method Remotely through touch pan Manual adjustment of sensorEmergency stop function Yes NoSize and shapeValueSystem configuration set-upCylindrical and slickCompact hardware configurationMinimal installation space requiredYour choice of systems(Two-Pallet and Multi-Pallet)Both offer excellent value giventheir superior quality and enhancedfunctionalityFast and advancedConfigure at the user interfaceusing each wireless sensor’sserial numberRectangular box formComplex hardware configurationAdditional installation spacerequiredOnly one system offered at arelatively high price, given itsfunctionalitySlow and traditionalA magnet is used to initiate thewireless sensor and base station tolook for each other and then linkPressure point installment No – seamless all-in-one unit Yes – at least two parts neededPressure measuring method Reports actual pressure value Reports binary value onlyPressure accuracyBattery capacityProgrammable pressurelimit options±50 PSI for a 5,000 PSI wireless sensor(±1% full scale)Designed by Electrochem forrugged environmentsOne 3.9V AA lithium brominechloride batteryUp to two programmable low or highpressure limits per wireless sensor±200 - 300 PSITypical off-the-shelf product –two 1.5V AA batteriesOnly one low pressurelimit per wireless sensor

Q&A’S FOR CNC WIRELESS SENSING SYSTEMSWhat is Electrochem’s Wireless Sensing Solution?Electrochem’s solution is an extremely accurate, wirelesspressure sensing system used to verify hydraulic pressurethat is sufficient to keep a part clamped before andduring CNC machining and/or metal forming. If hydraulicclamping pressure falls below or above a set of limits,the machine – and operator – will be alerted to initiatea “shut down” process.What is the difference between Electrochem’sTwo-Pallet and Multi-Pallet Wireless Sensing Solutions?The main differences between the Two-Pallet andMulti-Pallet Systems are as follows:What is a base station?The base station receives the measurements wirelesslytransmitted from the PS1. Additionally, the base stationsends the PS1 commands to go into “sleep” mode orto begin transmitting measurements. The base stationhas a password-protected touch panel display usedto configure your wireless systems. This touch panelalso displays the current pressure measurements ofthe active wireless sensors, as well as diagnostic andsystem alerts. The base station also communicates toyour machine while determining what pallet/fixture isgoing to be machined next – and alerts the machine if apressure limit is breached.WirelessSensors perBase StationWirelessSensorsMonitoredSimultaneouslyper Pallet/FixtureConnection tothe MachineTouch PanelDisplayDimensionsTwo-PalletSystemMulti-PalletSystem1 - 2 1 - 1272 1Relay and/or3 Digital I/O’sDB25connectorusing DigitalInputs andOutputs2.75” x 1.5” 4.75” x 3.5”How often do batteries need tobe replaced on the PS1?Electrochem’s own BCX lithium batteries are used topower the PS1. One 3.9V AA battery is needed to powerthe wireless sensor for up to one year; battery life isdependent on the transmission rate.How do you know when to replace a battery?The base station’s touch panel display will flashand display an error message stating it “cannotcommunicate with wireless sensor x.” This willindicate the battery needs to be replaced.What is the recommended maximum distancebetween the PS1 and base station to allow forreliable communication?The PS1 and base station have up to a 300-foottransmission range. Line-of-sight is not required forreliable transmission; however, the antennas cannotbe completely enclosed within metal.What is a Wireless PressureSensorOne (PS1)?A patented, self-contained wireless device thattransmits accurate pressure measurements wirelesslyto a suitable base station. In addition to pressure, thePS1 also transmits the battery voltage, temperatureat the pressure port and internal temperature of thewireless sensor. An internal battery powers the wirelesssensor up to one year.Will the PS1 reliably measure and transmit pressurereadings in the rugged, harsh environment ofa CNC machine?Yes, the PS1 has been designed to reliably function inthis type of environment. Its stainless steel body ando-ring sealed design prevents coolant and/or metalshavings from damaging the wireless sensor or affectingthe performance.

How can the PS1 be installed on my fixture?We recommend using Electrochem mounting bracketsto securely mount the PS1 to the fixture. Additionally,Electrochem offers a variety of pressure port fittingsthat are compatible with your hydraulic clamps.Will other wireless devices cause interference?No. Wireless devices, Bluetooth and Wi-Fi willnot affect – or be affected by – Electrochem’swireless sensing systems.Can a PS1 be connected to multiple base stations?A PS1 connected to a Multi-Pallet System can beconfigured to communicate with more than one basestation on different machines. This is helpful if you areusing the same fixture on multiple machines.How many PS1s can be used in the same facility?A single facility could have up to 1,000 wireless sensors.Each PS1 has a unique 4-digit serial number which isused to sync the wireless sensor with a base station.What is “sleep” mode? What happens when thewireless sensor’s pallet is not being machined?“Sleep” mode is a Multi-Pallet System default settingused to conserve battery life. When the PS1 isconnected to a pallet/fixture that is not currently beingmachined, it goes into “sleep” mode – and waits for acommand from the base station to begin transmittingpressure measurements.How will the base station and PS1 respond when themachine it is installed on loses power?The base station will lose power along with the machine –but it will maintain all of its settings. The PS1 is batteryoperated, so it will remain powered onand continue to link to its configuredbase station(s). The base station willlook for input from the machine whenpower is restored.How are the PS1 and base station(s)paired together?The 4-digit serial number located onthe PS1 is entered into the base stationand then automatically linked to thespecified pallet/fixture.How many pressure limitsare allowed per PS1?For the Two-Pallet System, one “low”pressure limit can be set for bothwireless sensors.For the Multi-Pallet System, two pressure limits areallowed for each PS1. Each can be configured as a “low”or “high” pressure limit. If all of the limits are the same,a global limit can be set.The pressure limits for both systems are configuredvia the password-protected touch panel display.Learn what our wireless sensing systems can do for you.To discover all the advantages of Electrochem’s complete solution for CNC machiningoperations, please call us at 716.759.5800. You can also find more information by visitingour website at www.Electrochem-Wireless.com.

Electrochem Solutions, Inc.10000 Wehrle Drive, Clarence, NY 14031 USA l ph 716.759.5800 l fax 716.759.2562www.Electrochem-Wireless.com