Machining center with an aerospace part and an edge device, a technician with a tablet sees vibration and spindle curves with an early warning

How bavius stops scrap before it happens

The Industrial Data Platform correlates spindle vibration, motor currents and NC data in real time. The Edge Analyzer alerts the operator immediately – even for batch size 1.

Discuss your project
Customer
bavius technologie GmbH
Industry
Machine tools
Services
Overall architecture, edge analytics, camera copilot
Technology
Industrial Data Platform, Edge Analyzer

Starting point

bavius technologie builds high-performance machining centers, including for aerospace. Process deviations should be detected before scrap occurs. With batch size 1, there is no historical comparison data for this.

Then there is setup: the workpiece has to be clamped and probed. Setup time and operating errors should go down in the process.

Implementation

codestryke was responsible for the overall architecture – from the cloud connection to the analyzer software directly on the machine. It is based on our Industrial Data Platform (IDP).

The Edge Analyzer combines spindle vibration, motor currents, torques and power consumption of the feed servo drives with tool, position and NC program data. It compares workpieces autonomously and alerts the operator immediately when deviations occur. Where comparison data is missing, CAM and simulation data serve as the reference.

A camera copilot captures the dimensions, raw material and machining status of the clamped workpiece in the work area. From this, it derives the clamping strategy with strap clamps and a safe probing strategy for the tool zero point. If strap clamps have not been removed before critical operations, live monitoring stops the machine.

Work area with spindle, vibration sensor and a camera measuring the workpiece; an edge device warns of scrap
Dashboard with inspected parts, one part was stopped before becoming scrap, next to it a stable spindle curve within the tolerance band

Result

Deviations are detected directly at the machine, without cloud latency. To do this, the Edge Analyzer correlates five signal sources. Parts with batch size 1 are monitored reliably as well.

The camera copilot reduces setup time and operating errors. Real-time dashboards and trend analyses show process, energy and condition data across the entire lifecycle.

Scrap rate
−30 %
Response time
< 50 ms

More references

All references

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