WattPilote Evolution Automotive V103 US Web

Tool wear and breakage monitoring system WattPilote
w w w . d i g i t a l w a y g r o u p . c o m
Drilling
Boring
Tapping
Deep drilling
Milling
Spot-facing
Turning
High-Volume Parts Production

Most important:
precise measurement
For each type of machine, WattPilote’s 0.01% power measurement
accuracy combined with its 50 kilohertz
one WattPilote solution sampling frequency accommodates all
WattPilote is the generic name of the power types of electric motors (AC, DC with
monitoring product line developed by the company brushes, DC brushless, and stepper) and
Digital Way. WattPilote are used to measure tool variable-frequency drive electronics. A
wear and to avoid tool breakage on all types of complete range of monitoring systems is
metal-cutting machines. available for motors rated from 250 watts
to 100 kilowatts.
Adaptable to
all types of machining
To accommodate high-speed machines as well as
traditional machines, WattPilote provides an Machining centers Single
adjustable sampling rate. So it is possible to control 1 controlled motor | axis or spindle | up to 120 different machining cycles
machining cycles with durations as short as 0.07
seconds and as long as 50 minutes. It is very easy
Special machines and Transfer Transfer
to install WattPilote on an existing machine already
in production, because all the installation is done in 1 controlled motor | axis or spindle | up to 15 different machining cycles
the electrical cabinet.
Machines with 2, 3 or 4 spindles Dual, Triple or Quad
2, 3 or 4 controlled motors | spindles | 2, 3 or 4 x 120 different machining cycles
Lathes or turning centers Turning

3 controlled motors | 2 x axis + 1 x spindle | 3 x 120 different machining cycles
Grinding or balancing machine Contact

1 controlled motor | axis or spindle | up to 120 different machining cycles
Convenient installation
in the electrical cabinet
WattPilote combines power measurement, signal processing, and
Fieldbus interface in the same box. Its installation is very simple
since all wiring is done in the electrical cabinet.
User-friendly
and easy to adjust
A full range of fieldbus options A PC or PC-compatible numeric control connected to a WattPilote
The flexible communication module integrated in allows the display and graphical analysis of machining power
WattPilote Evolution supports all major Fieldbus curves, faults, and tool wear.
and Real-Time Ethernet protocols.
Easy to understand data history and

PLC Interfaces
graphical power curves

Ethernet/IP
PowerLink
The WattPilote memory is able to store, for each of the last 65,000
DeviceNet
EtherCAT
ProfiBus
machining cycles, a report including machining date and time,

ProfiNet
control mode used (learning, re-machining, collision control … ),

Smart
control result (power, energy, or derivative alarms) and the value of

the tool wear rate. Moreover, WattPilote memorizes the complete
curves of the 30 most recent normal machining cycles, along with
the 30 most recent faults.
WattPilote controls and prevents tool breakage on

machines carrying out repetitive operations.
WattPilote analyses the electrical power absorbed by a
spindle or axis motor to determine tool condition.
Energy control Detection at the end of cycle

WORN TOOL MISSING TOOL MISSING PART
By monitoring tool wear in real-time, WattPilote maximizes the
number of parts machined by any single tool and minimizes the Wear of one drill:
after 550 parts
chance of tool breakage. Tool wear impacts energy consumption.
When tools begin to wear out, the energy required to complete the
machining operation increases.
Using this principle, WattPilote verifies that the energy used by each
tool during each part cycle doesn't overshoot the wear threshold
programmed by the user.
During process prototyping, machining energy can also be used to
compare and to select the most efficient cutting tool geometry or the
best tool sharpening method.
Power control Instantaneous detection

DOUBLE
TOOL BREAKAGE MISSING TOOL
MACHINING
When a tool breakage occurs, reaction time must be quick to protect
the machine, the tool-holder, and to limit the production of out-of- 20 Kilowatt spindle:
1mm drill
spec parts. Only a real-time monitoring strategy, such as power
monitoring, meets this requirement.
WattPilote works by defining a “normal” power curve based upon Drill
breakage
machining a typical part with a new tool. It uses this curve to create
the minimum and maximum power limits that define the “normal”
machining process.
Each consecutive machining cycle, creates a new power curve that
is compared with the first one.
Tool breakage, missing tools, and double machining are immediately
detected when the process limits are exceeded.
Derivative control (patented) Instantaneous detection

PART IN WRONG
TOOL BREAKAGE INSERT BREAKAGE
POSITION
When a breakage occurs during a reaming operation done with
complex tools or during a drilling / tapping operation on a multi- Multi-spindle head with 15 taps:
3 M7 taps, 3 M8 taps, 9 M10 taps
spindle head, the change in power is very small. When milling and
turning operations are done on rough parts, the power variation from
part to part can be quite large. Breakage of
The derivative control used by WattPilote amplifies small and fast one M7 tap
power variations (like those seen during the breakage of one milling
cutter insert) and ignores power variations due to rough parts or to
part hardness changes. So tool and insert breakages on multi-
spindle heads and on rough parts can be detected more reliably.
Double One M8 tap accidentally

machining exchanged with one M10 tap
For each type of machine, one WattPilote solution
Remote
maintenance system
Internet
MayDayBox
Switch
Transfer machine 8 units
Local network
Local supervision WP-Visu-C
system
WM-B10
Machining center with 4 spindles
SW-A05
WP-Visu-C Local supervision

Flexible unit system
WM-B10
Monitor critical machining

operations
Often critical operations performed with
Single-spindle machining small and fragile tools must be
centers and special machines monitored. Due to the measurement
accuracy achieved by Digital Way’s
WattPilote Single has been designed especially
unique control algorithms, WattPilote can
for one-spindle machines using a significant
monitor all tools, even the smallest:
number of tools: machining centers, special
controlling a 0.07 second machining
machines with tool changers.
cycle using a 1mm drill on a 20kW
spindle is possible.
Avoid scrap and
extend tool life
The objectives of real-time machining monitoring
are to avoid scrap parts, to increase tool life, and to
reduce machine downtime.
WattPilote system What For?
Indispensable to ensuring your production quality, the
WattPilote is the best solution to reduce your manufacturing
costs, avoid producing scrap and to protect your machines.
On any machining center How ?

The flexible communication module integrated in WattPilote
supports a wide range of Fieldbus options and allows
installation on any machine
Unique sensing technology Why ?

WattPilote has the ability to monitor the condition of a wide
range of cutting tools – from a multi-insert milling cutter to
small-diameter drills and reamers.
Install outside
the machining environment
Reduce machine downtime Only one box, containing the power measurement sensors, signal
WattPilote allows special machines or machining processing, and Fieldbus interface, is mounted inside the electrical
centers with pallet changers to work while cabinet. The system is compact, easy to install, and resistant to
untended. When tool wear or breakage is detected, environmental influences (cutting oil, swarf, temperature,
the machine stops, changes the tool, and then mechanical vibrations, and electromagnetic noise).
starts machining again, either on the same part or
on the following part.
Diagnostic and supervision functions

available on numeric controls
Visu-CN-C software is an effective diagnostic and supervision tool.
It is a user-friendly software package that can be loaded directly onto PC-compatible
numeric controls. The operator can display machining cycles, tool wear condition, and fault
curves. He can modify the control tolerances, and acknowledge faults and tool changes.
Spindle preventive maintenance

WattPilote is designed for real-time machining monitoring. However, it can also periodically
monitor preventative maintenance machine cycles to record the spindle signature and
detect mechanical faults: ball-bearing wear, lubrication issues …
Evolution Model range
Machine control panel Electrical cabinet
NC
CNC Frequency
converter
24V
DC PLC
1A
WE-M10
WE-M10 WE-M01
RJ-P01 SW-A05 WP-CN-S032
Machine Tool
Laptop PC
(Backup) WP-Visu-C
PLC Spindle
WL-E05
Single-spindle machine tool with numeric control
General characteristics Evolution

Drilling Max number of different machining cycles 120
Wear Minimum machining cycle time 0.07 sec.
Drill breakage Maximum machining cycle time 50 minutes
Missing tool Reaction speed 0.005 sec.
Saved machining cycle curves last 30
Saved faults last 30
Saved wear rate last 65,000
Power, derivative, energy control Simultaneous
Boring Measurement accuracy
0
0.01 /0
Wear
Double boring Technical characteristics Single
Reamer breakage Power supply 24 VDC  10%, 0.5 A
Insert breakage PLC Protocol - Fieldbus ProfiNet IO-RT
Profibus-DP I/O Slave
DeviceNet Slave
Ethernet/IP
Tapping EtherCat
Wear Smart (Digital I/O)
Double tapping Supervision interface Ethernet, 10/100 Base TX
Tap breakage Fast Inputs 24 VDC type II, 15 mA
Fast Outputs Work contact static relay 24VDC
Ambient temperature 0 ... 50°C
Assembly Symmetrical rail DIN EN50 023
Dimensions L 170 mm, W 105 mm, H 96 mm
Deep hole Protection rating IP 20
drilling Weight 1kg 260
Wear
Drill breakage
WattPilote Single Evolution reference Part Nr.
Missing tool WP–C X – X 000
ProfiNet IO-RT : N 000 : Power rating in kW
ProfiBus DP Slave : B S : Three-phase spindle motor
Milling DeviceNet Slave : D H : High-frequency three-phase spindle motor
Wear Ethernet TCP/IP : E A : Three-phase axis motor
Double milling Smart Interface : S D : Direct current motor
Insert breakage Example - WP-CN-S032 : WattPilote Single Evolution – 32KW three-phase spindle – ProfiNet interface
Monitor critical machining

operations
Machining centers and special machines
Machining centers and with 2, 3, or 4 spindles are increasingly
special machines used to improve production rates. To
monitor the most critical operations on
with 2, 3, and 4 spindles these types of machines, WattPilote
Dual, Triple or Quad has two, three or
WattPilote Dual, Triple and Quad are tool wear and four independent power channels for
breakage monitoring systems especially designed measurement and control: tool wear and
for 2, 3, or 4-spindle machines: machining breakage monitoring is as simple,
centers and special machines. reliable, and accurate as it is on single-
spindle machines.
For dependent or independent
spindle machines
Power absorbed by each spindle is measured and
controlled independently: the 2, 3, or 4 spindles of
the machine can be mechanically interconnected or
completely independent. Each spindle can use a
similar or a different type of spindle motor. WattPilote Dual
WattPilote Dual ensures production quality, reduces
manufacturing cost and avoids producing scrap on any
2-spindle machining center or special machine.
WattPilote Triple
WattPilote Triple is the most efficient solution to monitor
wear and tool breakage on 3-spindle machining centers and
special machines.
WattPilote Quad
WattPilote Quad is ideal to monitor tools on any machining
centers and special machines with 4-spindles, designed for
the production of parts in large volume.
Power data curves that are
easy to understand
WattPilote memorizes the last 65,000 machining
reports (date, time, control mode, and fault), the
last 30 machining curves, and the last 30 fault
curves for each spindle.
Compact, installation within
the electrical cabinet
WattPilote Dual, Triple and Quad have independent wear and breakage
monitoring systems in the same box, only the wiring with the PLC is in
common, so the system is compact and easy to install.
Diagnostic and supervision functions

available on numeric controls
The Visu-CN-C software is an effective diagnostic and supervision tool.
It is a user-friendly software package that can be loaded directly onto PC-compatible
numeric controls. The operator can display machining cycles, tool wear condition, and fault
curves. He can modify the control tolerances, and acknowledge faults and tool changes.
NC
CNC Frequency Frequency
converter converter
24V
DC PLC
2A
WE-M10
WE-M10 WE-M01
RJ-P01 SW-A05 WP-DN-S032

Laptop PC Machine Tool
(Backup)
WP-Visu-C
PLC Spindle Spindle
WL-E05
2 spindle machine tool with numeric control

Drilling Max number of different machining cycles 2 x 120
Saved machining cycle curves 2 x last 30
Saved faults 2 x last 30
Saved wear rate 2 x last 65,000
0
0.01 /0
Wear
Double boring Technical characteristics Dual
DeviceNet Slave
Ethernet/IP
Tapping EtherCat
Double tapping Supervision interface Ethernet - 10/100 Base TX
Wear
Drill breakage
WattPilote Dual Evolution reference Part Nr.
Missing tool WP–D X – X 000
Insert breakage Example - WP-DN-S032 : WattPilote Dual Evolution – 2 x 32KW three-phase spindle – ProfiNet interface
NC
CNC Frequency Frequency Frequency
converter converter converter
24V
DC PLC
3A
WE-M10
WE-M10 WE-M01
RJ-P01 SW-A05 WP-GN-S032

(Backup)
WP-Visu-C
PLC Spindle Spindle Spindle
WL-E05

0
0.01 /0
Wear
Double boring Technical characteristics Triple
DeviceNet Slave
Ethernet/IP
Tapping EtherCat
Wear
WattPilote Triple Evolution reference Part Nr.
Drill breakage
Missing tool WP–G X – X 000
Insert breakage Example - WP-GN-S032 : WattPilote Triple Evolution – 3 x 32KW three-phase spindle – ProfiNet interface
NC
CNC Frequency Frequency Frequency Frequency
converter converter converter converter
24V
DC PLC
3A
SW-A05
WE-M10
WE-M10 WE-M01
RJ-P01 WP-QN-S032
(Backup)
WP-Visu-C
PLC Spindle Spindle Spindle Spindle
WL-E05

0
0.01 /0
Wear
Double boring Technical characteristics Quad
DeviceNet Slave
Ethernet/IP
Tapping EtherCat
Wear
Drill breakage
WattPilote Quad Evolution reference Part Nr.
Missing tool WP–Q X – X 000
Insert breakage Example - WP-QN-S032 : WattPilote Quad Evolution – 4 x 32KW three-phase spindle – ProfiNet interface
Monitor multi-spindle heads

Multi-spindle heads can provide high-
Multi-station special machines performance in production, but tool
breakages are more difficult to detect on
and transfer machines these heads than on single-spindle
WattPilote Transfer has been especially designed heads, and they can cause serious
for multi-station machines which perform only a few consequences to the part quality and to
operations on each machining unit: multi-station machine downtime. Mechanical
special machines and transfer machines. breakage monitoring solutions are
complex to put into production.
WattPilote Transfer has been designed
Monitor tools without any loss to ensure machining quality while
in cycle time maintaining a high machine output rate.
The monitoring is performed in real-time during the By combining high measurement
machining cycle, with no impact on the cycle time. Any accuracy with powerful control
tool breakage is immediately signaled to the machine. algorithms, WattPilote Transfer can
detect the breakage of one drill in
eighteen.
Detection at the end of cycle Energy control

Tool wear
Missing tool
Missing part.
Instantaneous detection Power control

Tool breakage
Missing tool
Double machining
Instantaneous detection Derivative control

Tool breakage
Insert breakage
Installed outside of Part in wrong position
the machining environment
Only one box, containing power measurement
sensors and the data-processing hardware, is Diagnostic and supervision functions
mounted in the electrical cabinet. The system
available on a central unit
is easy to install and insensitive to machining Visu-CN-C software can be loaded directly onto an industrial
conditions (cutting oil, swarf, tem per atur e, supervision PC for the machine or onto a PC-compatible numeric
m ec hanic al vibrations , elec tr om agnetic control. The operator can display the machining cycles, tool wear
nois e). condition, and the fault curves for each station. He can also modify
the control tolerances, and acknowledge faults and tool changes.
Autonomous control for each unit

It is necessary to install one WattPilote Transfer to control each
machining station. Self-contained, it has its own inputs/outputs
wired in the electric cabinet. The WattPilote systems on the same
machine are part of a network and are connected to a central
supervision system. This distributed intelligence architecture is
ideal for use with input / output modules.
Electrical cabinet Electrical cabinet – Unit 1 Electrical cabinet – Unit 2 Electrical cabinet – Unit 3
PLC WE-M20
WE-M15
WE-M02 WE-M10
Frequency Frequency Frequency
SW-A05 converter converter converter
RJ-P01
WE-M05
WP-TN-S016 WP-TN-S016 WP-TN-S016
WL-E05
WP-Visu-C
Spindle Spindle Spindle

WM-B10
Laptop PC
(Backup) Electrical cabinet Machine Tool
Transfer machine, 3 units with supervision on WM-B10 monitor
PLC
Drilling Max number of different machining cycles 15
Saved machining cycle curves last 30
Saved faults last 30
0
0.01 /0
Wear
Double boring Technical characteristics Transfer
Reamer breakage Power supply 24 VDC  10%, 0.5A
DeviceNet Slave
Ethernet/IP
Tapping EtherCat
Wear
Drill breakage
WattPilote Transfer Evolution reference Part Nr.
Missing tool WP–T X – X 000
Insert breakage Example - WP-TN-S016 : WattPilote Transfer Evolution – 16KW three-phase spindle – ProfiNet interface
Measure
spindle power and axes power
Now, lathes and turning centers have
Automatic lathe access to a simple and efficient
and turning center machining monitoring system. To
control machining operations efficiently,
WattPilote Turning is a tool wear and breakage
WattPilote Turning performs three
monitoring system specially designed for all turning
measurements: two measurements from
machines.
the axes and one from the spindle. For
each machining operation, several
Decrease machine downtime measurements are used (sometimes in
combination) to determine tool condition.
This system has been developed to optimize tool
management on turning machines and to prevent
tool breakage by detecting wear and damaged
inserts. The machine stops when a problem
occurs and before it, the tool holder, or the part is
seriously damaged.
Power measurement Spindle

The measurement of the main spindle is very effective for
monitoring external machining for roughing operations and
for finishing operations.
Torque measurement X and Z axis

Monitoring of the axes is the best solution when small tools
work at the center of the part, but also for the slicing / cut-off
operations with a constant surface feed rate.
Maintain production quality Power measurement Driven tool

WattPilote Turning stops the machine as soon as On turning centers, the measurement of the driven / rotating
worn or chipped inserts are detected. This ensures tool allows monitoring of drilling, tapping and all milling
that all parts are machined with tools that are in operations.
good condition. WattPilote Turning helps maintain
good production quality.
Compact installation within the electrical cabinet

WattPilote Turning combines three independent measurements of power in the same box.
The connection to the PLC is the only thing in common with the three channels: so the
system is compact and wiring it is easy. WattPilote is mounted in the electric cabinet, far
away from the machining area and its abusive conditions.
Diagnosis and supervision functions available

on the CNC screen
Visu-CN-C software is an effective diagnostic and supervision tool that can be integrated
directly into the CNC.
The operator can display machining cycles, tool wear condition and fault curves. He can
also modify the control tolerances, and acknowledge faults and tool changes.
NC
CNC
24V Frequency Frequency Frequency

DC PLC converter converter converter
3A
SW-A05
WE-M10
WE-M10 WE-M01
RJ-P01 WP-LN-S032/A008
Machine Tool
Laptop PC
(Backup) WP-Visu-C
PLC X Z Main
WL-E05 Axis Axis Spindle
Turning center with 30kW spindle and 10A axis motors.

Max number of different machining cycles 120
Slide-turning
Tool wear Minimum machining cycle time 0.07 sec.
Maximum machining cycle time 50 minutes
Insert chipping
Reaction speed 0.005 sec.
Insert breakage Saved machining cycle curves last 30
Missing tool Saved faults last 30
Raising Saved wear rate last 65,000
Tool wear Power, derivative, energy control Simultaneous
0
Insert chipping Measurement accuracy 0.01 /0
Insert breakage Technical characteristics Turning
Missing tool Power supply 24 VDC  10%, 1.3 A
Slicing/Cut-off PLC Protocol - Fieldbus ProfiNet IO-RT
Tool wear Profibus-DP I/O Slave
DeviceNet Slave
Insert chipping
Ethernet/IP
Insert breakage EtherCat
Missing tool Smart (Digital I/O)
Supervision interface Ethernet - 10/100 Base TX
Drilling
Tool wear Fast Inputs 24 VDC type II, 15 mA
Drill breakage Ambient temperature 0 ... 50°C
Missing tool Assembly 4 x screw M5
Boring Dimensions L 292 mm, W 105 mm, H 135 mm
Tool wear Protection rating IP 20
Weight 2kg 560
Insert chipping
Insert breakage WattPilote Turning Evolution reference Part Nr.
Missing tool
WP–L X – S 000 / A000 / S000
Threading Optional driven tool
ProfiNet IO-RT : N 000 Power rating in kW
Tool wear ProfiBus DP Slave : B X and Z Axis
Insert chip DeviceNet Slave : D 000 Power rating in kW
Insert breakage Ethernet TCP/IP : E Main spindle
Missing tool Smart Interface : S 000 Power rating in kW
Example - WP-LN-S032/A008 : WattPilote Turning Evolution - 32 kW Main Spindle / 12 A axis – ProfiNet interface
Human safety
With WattPilote Contact an operator
Contact detection never needs to approach the process for
a visual inspection to verify tool / part
Tool / Part contact. Contact detection happens
WattPilote Contact is a system designed to detect automatically and is very repeatable: the
the contact between tool and part via power part quality does not change.
measurement.
This system is easily installed on all types of
machines and it automates actions that have
required human intervention in the past: verifying
spark formation during grinding, regulating Shorten machining time,
pressure during planing or brushing, adjusting
increase productivity
contour during deburring operations, detecting the
beginning of machining on balancing drills, etc… WattPilote allows the gap between the tool and the part to be traversed
much faster than at machining speed. As soon as the tool touches the
part, WattPilote alerts the machine and machining speed is activated
immediately.
WattPilote also detects the end of machining in order to stop the
machine cycle as soon as the tool leaves the material.
Instantaneous detection Power control

Contact tool / part
Detect end of machining
Missing tool
Instantaneous detection Derivative control

Contact tool / part
Detect end of machining
No sensors are installed in the machining environment

One box containing sensing elements and the software is mounted within
the electrical control cabinet. The system is compact, easy to install, and
insensitive to environmental effects (oil, chips, temperature, mechanical
vibrations, electromagnetic noise, etc.).
Adjust system parameters and monitor the process

System parameters and process curves are displayed by the WP-Visu-C software
- configuration mode allows parameter adjustment
- monitoring mode displays power curves and system status in real-time.
WP-Visu-C has a graphical interface that allows you to see subtle changes in the
manufacturing process. It is easy to optimize cutting parameters to increase the part quality
and reduce cycle times.
Once you have finished the adjustments, the PC can be disconnected and WattPilote
Contact will run completely automatically.
Interruption
NC
CNC
24V Frequency
DC PLC converter
1A
WE-M10
WE-M10 WE-M01
RJ-P01 SW-A05 WP-AN-S032
Machine Tool
Laptop PC
(Backup) WP-Visu-C
PLC Spindle
WL-E05

Grinding Max number of different machining cycles 120
Contact detection Minimum machining cycle time 0.07 sec.
Mould/part Maximum machining cycle time 50 minutes
Reaction speed 0.005 sec.
Optimization of the Saved machining cycle curves last 30
feed rate Saved faults last 30
0
Measurement accuracy 0.01 /0
Polishing
Contact detection Technical characteristics Contact
polishing tool/part Power supply 24 VDC  10%, 0.5 A
PLC Protocol - Fieldbus ProfiNet IO-RT
Optimization of the Profibus-DP I/O Slave
feed rate DeviceNet Slave
Ethernet/IP
EtherCat
Smart (Digital I/O)
Brushing Supervision interface Ethernet - 10/100 Base TX
Contact detection Fast Inputs 24 VDC type II, 15 mA
brush/part Fast Outputs Work contact static relay 24VDC
Pressure Assembly Symmetrical rail DIN EN50 023
management Dimensions L 170 mm, W 105 mm, H 96 mm
Protection rating IP 20
Weight 1kg 260
Boring WattPilote Contact Evolution reference Part Nr.
Contact detection
tool/part WP–A X – X 000
Detection of the ProfiBus DP Slave : B S : Three-phase spindle motor
finished boring DeviceNet Slave : D H : High-frequency three-phase spindle motor
Ethernet TCP/IP : E A : Three-phase axis motor
Smart Interface : S D : Direct current motor
Example - WP-AN-S008 : WattPilote Contact Evolution – 8KW three-phase spindle – ProfiNet interface
Optional 3-axis
accelerometer sensor
This SafePilote option is a 3-axis accelerometer
sensor and processor specially designed and built
in Digital Way’s lab to provide you with the most
effective means for protecting your machines
during rapid movement.
Mounted on your machine’s spindle, this powerful
system also allows you to record vibration data Why using this option ?
associated with the conditions of machine use or Not essential for tool monitoring and quality parts ensuring,
with tooling quality. SafePilote option is however recommended for protecting machine
during all phases where the WattPilote system is not active such
as movements in rapid (G0) and changes tools
Vibration monitoring is a key factor to ensure the quality your
production, check your tooling and machine components. This is
also the fastest way to detect a collision and stop your machine
fast enough to prevent damages and downtimes. Consequences of
a crash during a machining operation are generally catastrophic:
- Broken Part or Tool-holder,
- Damaged spindle
- Need to remake all mechanical set-up of the machine
- Long downtimes
- Stop of production
SafePilote option What for ?

To minimize consequences of crash and
reduce the repair costs.
Reduce cost How ?

Installed on the machine, SafePilote option detect very faster crash
and stop immediately the movements of axis.
On many application Why ?

Small, easy to install and adjust, SafePilote option can be successfully applied on
most kind of machines: Machining centers, turning centers, grinding machines..
Minimizing crash damage

When machine stop is decided by an over-current
alarm on an axis movement, it’s often too late to Compact and easy to install
avoid large damages on the spindle / tool / part With this option, WattPilote combines power measurement, power
fixture, leading to long downtimes and increasing and vibration signal processing, but also the Fieldbus interface in
your manufacturing costs. the same box.
Of course, the SafePilote option will not prevent the Its installation is very simple : vibration sensor is fixed on the rear
crash, but it’s extremely fast reaction time will allow of spindle and connected to WattPilote with an communication
a much faster machine stop and thus a drastic cable that can be mixed with power cable in kabelschlepp, then all
reduction of the repair costs. wiring is done in the electrical cabinet.
SafePilote - Machine Tool protection and condition monitoring
NC Interruption
CNC
24V Frequency
DC PLC converter
3A
SW-A05
WE-M10 WE-M01
WE-M10 WE-M01
RJ-P01 WP-CN-S032+SP
Machine Tool
Laptop PC CA-M15
(Backup) WP-Visu-C
PLC Spindle
WL-E05 AG-03M
Technical characteristics Sensor

WattPilote Technology 3-axis digital accelerometer
Measurement range ± 16 g
Sensitivity 4mg
Tool Wear Maximum shock 10,000 g shock survival
Sampling rate 3200 Hz
Tool breakage Ambient temperature -20 ... 85°C
Dimensions L 45 mm, Diam. M12
Insert breakage Protection rating IP 67
Weight 15 gram
Missing tool Technical characteristics Processor
Number of different process 120 (15 with WattPilote Transfer)
Double machining Reaction speed 0.5 millisecond
Saved events last 1 500 000
Tool/Part contact Saved events curves last 10 000
Fast Inputs 24 VDC type II, 15 mA
Communication protocol with sensor Numeric (CAN Network)
SafePilote
Maximum length of sensor cable 80 meters
WattPilote Evolution reference Part Nr.

Collision Single - Transfer - Contact - Turning
Reference WattPilote + SP
Excess Vibration SP : SafePilote Option
Example
WP-CN-S032+SP : WattPilote Single Evolution – 32KW three phased spindle – ProfiNet interface – SafePilote option
Chatter WP-AN-S016+SP : WattPilote Contact Evolution – 32KW three phased spindle – ProfiNet interface – SafePilote option
WP-LN-S032/A008+SP : WattPilote Turning Evolution - 32 kW Main Spindle / 12 A axis – ProfiNet interface
Balance Dual – Triple - Quad
Reference WattPilote + SP 0
Machine analyse 0 : Number of SafePilote channel
SP : SafePilote Option
Check spindle Example
WP-DN-S032+SP2: WattPilote Dual Evolution – 32KW three phased spindle – ProfiNet interface – 2 channels SafePilote
WP-QN-S016+SP1: WattPilote Quad Evolution – 16KW three phased spindle – ProfiNet interface - 1 channel SafePilote
User-friendly software
The Windows OS environment is used to
make all adjustments to WattPilote. Each
WattPilote set-up and device is given a name and then
process supervision recognized automatically with each new
connection. The WP-Visu-C software
A system set-up program is software .
available for the
automatically creates all the files and
supervision of WattPilote devices as a part of
directories necessary for the WattPilote
Digital Way’s range of products for tool wear and
during initial connection. So you do not
breakage monitoring.
need to be a Windows expert to use
WP-Visu-C effectively.
Interpret the machining curves

Developed for PCs running under a Windows
environment, WP-Visu-C is an invaluable aid for Transfer
the visualization and graphical interpretation of
Multi-station special and transfer machine
machining cycles.
Single
One spindle Machining center and special machine
Dual
Machining center with two spindles
Triple
Machining center with three spindles
Quad
Machining center with four spindles
Turning
This machining analysis software is very simple to
Automatic lathe and turning center
use and makes it possible not only to visualize and
optimize the adjustment of your WattPilote, but
also to save details about the machining curves in Contact
order to compare them later. Grinding and balancing machine
Multilingual operation
A configuration screen accessible from the main menu makes it possible to choose the
human interface language without needing to restart Windows or WP-Visu-C.
Graphical display
of machining power curves
WP-Visu-C is particularly useful when numerous machining cycles have been recorded. All
settings can be displayed graphically and the impacts of changes to any parameter appear
immediately on the graphical display and the limits are automatically adjusted. However, the
changes are not implemented in the WattPilote hardware until they are downloaded. This
allows new limit strategies to be tested on historical data without the risk of generating false
alarms.
Set-up and supervision software
Hardware requirements to use WP-Visu-C

The WP-Visu-C software is designed to operate on an IBM or
compatible PC under the Windows environment.
The following hard- and software components are recommended:
Computer : i5 processor. A more powerful processor will
increase performance, especially with regard to
graphics and file back-up.
Windows : Version XP / 2000 / Windows 7 / Windows 8
Memory : 256 Mb RAM minimum.
Hard disk : 25 Gb are necessary for the software and file
back-ups.
Interpret the machining curves

The “work screen” is used for the graphical adjustment of tolerances and to
interpret the machining curves. The "settings screen" is directly accessible
from the work screen. It is a simple matter to modify a parameter and to see
its direct influence on the tolerance ranges. Part of the screen is set aside for
displaying the adjustment parameters, while another area is intended for the
machining details (including the device reference and the machining reference
and number, and an optional commentary on a fault curve, for example).
Adjust the parameters for each machining cycle

The system parameters can be read or downloaded. These operations are
carried out either for individual machining cycles or for a series of cycles. A
definition file for each machining operation can be printed upon request.
Visualize tool wear

It is important to detect tool breakage on a machine, but wear
detection is also important, since it makes it possible to avoid
breakage. The wear curve can be displayed upon request. The
analysis is useful both for the selection of wear thresholds and
for the choice of efficient tool geometries and sharpening
methods.
WattPilote - the perfect solution for

every type of machine and every application
SafePilote
Transfer
Turning
Contact
Single
Triple
Quad
Dual
Selection guide
Automatic boring machines with single tools  
Boring / deep hole drilling machines or multi-spindle machines  
Transfer machines and multi-station special machines  
Fully automatic milling machines 
Single-spindle machining centers and special machines 
Machines
Double-spindle machining centers and special machines 

Three-spindle machining centers and special machines 
Four-spindle machining centers and special machines 
Fully automatic turning machines and turning centers 
Special turning machines    
Surface, cylindrical, internal, and centerless grinding machines  
Balancing machines  
Shaving machines 
Gear cutting machines 
Boring or deep hole drilling with single tools      

Boring, drilling or tapping using a multi-spindle head     
Machining / Applications
Drilling with a boring bar or a tool with multiple inserts      

Machining with complex cutting tools       
Boring with ¾ borer     
Rough machining, machining of raw parts      
Finishing milling      
Turning / rough milling, turning work on a rough part    
Finish turning work    
Detection of contact tool / part    
Detection of contact tool / part + tool breakage and wear detection   
Machining of sandwiched materials (detecting each material change)   
Beam drilling (cycle optimization)  
Crankshaft shaving 
Gear cutting  
 : Optimal performance
 : Works under certain circumstances
 : Not recommended
 : SafePilote option recommended
Digital Way Digital Way Group – WattPilote Automotive range - Version 1.04 - US
F R AN C E C H I N A
Digital Way SAS – Saint Etienne Tél.: +33 (0)4 77 74 92 50 Digital Way – Shanghai Tel.: +86 21 52 58 14 05
contact@digitalwaygroup.com elliot.chen@digitalwaygroup.com
U N I T E D S TAT E S E S PAÑ A
Digital Way Inc. – Michigan Tel.: +1 -8 0 5 -4 3 3 -2 8 2 0 Danffor – Eibar Tel.: +34 943 820 464
john.cosic@digitalwaygroup.com danffor@danffor.com
DEUTSCHLAND S O U T H K O R E A
Digital Way – Frankfurt / Main Tel.: +49 069 9621 76 64 BR ENT Tel.: +82 10 8890 0783
Joachim.hoelss@digitalwaygroup.com bill.rhee@digitalwaygroup.com
ITALIA P O L AN D
Angiolini Franco – Milano Tel.: +39 342 143 2840 Ai-Tech – Bielsko-Biala Tel.: +48 601 695 755
Franco.angiolini@digitalwaygroup.com digitalway@ai-tech.com.pl
Tool Monitoring

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Tool wear and breakage monitoring system WattPilote

High-Volume Parts Production

Lathes or turning centers Turning

Grinding or balancing machine Contact

Easy to understand data history and

graphical power curves

machining cycles, a report including machining date and time,

control mode used (learning, re-machining, collision control … ),

control result (power, energy, or derivative alarms) and the value of

WattPilote controls and prevents tool breakage on

Energy control Detection at the end of cycle

Power control Instantaneous detection

Derivative control (patented) Instantaneous detection

Double One M8 tap accidentally

Machining center with 4 spindles

WP-Visu-C Local supervision

Monitor critical machining

On any machining center How ?

Unique sensing technology Why ?

Diagnostic and supervision functions

Spindle preventive maintenance

RJ-P01 SW-A05 WP-CN-S032

Single-spindle machine tool with numeric control

General characteristics Evolution

Monitor critical machining

Diagnostic and supervision functions

RJ-P01 SW-A05 WP-DN-S032

2 spindle machine tool with numeric control

General characteristics Evolution

RJ-P01 SW-A05 WP-GN-S032

3 spindle machine tool with numeric control

General characteristics Evolution

4 spindle machine tool with numeric control

General characteristics Evolution

Monitor multi-spindle heads

Detection at the end of cycle Energy control

Instantaneous detection Power control

Instantaneous detection Derivative control

Autonomous control for each unit

Spindle Spindle Spindle

Power measurement Spindle

Torque measurement X and Z axis

Maintain production quality Power measurement Driven tool

Compact installation within the electrical cabinet

Diagnosis and supervision functions available

24V Frequency Frequency Frequency

Turning center with 30kW spindle and 10A axis motors.

General characteristics Evolution

Instantaneous detection Power control

Instantaneous detection Derivative control

No sensors are installed in the machining environment

Adjust system parameters and monitor the process

RJ-P01 SW-A05 WP-AN-S032

Single-spindle machine tool with numeric control

General characteristics Evolution

SafePilote option What for ?

Reduce cost How ?

On many application Why ?