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Makino Health Maximizer (MHmax) Tutorial

Predict Your Machine Health with Makino’s MHmax Predictive Analytics

Table of Contents

INTRODUCTION

The Makino Health Maximizer (MHmax) provides predictive maintenance capabilities that assess the health of major machine subsystems. The science behind MHmax enables manufacturers to reduce unplanned downtime by facilitating proactive actions through preventative maintenance. This cutting-edge technology employs sensors combined with an onboard computer programed with machine-learning software.
 
MHmax allows companies to:
  • Minimize cost of unplanned downtime
  • Receive push alerts through text and email notifying of concerning symptoms
  • Inform maintenance staff of the preventative maintenance schedule with a consolidated report
  • Reduce troubleshooting time by pointing to the problem area
  • View easy-to-understand machine condition summaries

HOW IT WORKS

HOW IT WORKS
Sensors are added to each machine to monitor four main subsystems: the spindle, hydraulic system, coolant system, and mechanical systems. These sensors measure flow rate, pressure, temperature, vibration, and position timing to provide the data needed to feed the IoT machine-learning software developed by Makino data scientists. The sensor package was selected to focus on areas that have the greatest frequency of incidents, the largest risk associated with recovery, and the highest potential duration of downtime associated with failures.
 
This predictive maintenance software incorporated 15 years of service records and millions of data points in order to fully “learn” the factors that influence and predict machine down time. Each machine has a dedicated onboard computer installed with a processor that runs MHmax's powerful predictive technology. With a dedicated computer, there is no concern of MHmax shutting down your machine, as the machine will run without MHmax functioning.

| Spindle Health

| Spindle Health
Accelerometers are used to monitor spindle bearing frequency and this data is fed into the proprietary AI software developed by Makino. The software analyzes the data and determines the current health of the spindle which is indicated by a red/yellow/green gauge. In addition, a determination is made if the spindle has experienced an abnormal deceleration or "wreck" which potentially has damaged the spindle. Lastly, the sensors monitor whether a cutting tool is showing signs of imbalance while in the spindle. All of this is reported on a Spindle Health monitoring page.

 

| Coolant System Monitoring

| Coolant System Monitoring
Flow rate and temperature gauges are used to monitor the machine's overhead shower and nozzle coolant systems to make sure the pumps, valves, and overall delivery system is functioning correctly. During the initial installation, a default setting establishes the acceptable range for the measurements based on Makino's analysis of historical data. As the machine runs in the shop with the operational parameters, the machine-learning software recognizes trends and adapts the acceptable range to allow for potential tighter control of these indicators. If a shop is running a critical process that has specific flow or temperature requirements, the system can be adjusted with user-controlled settings based on the known conditions.

| Hydraulic System Monitoring

| Hydraulic System Monitoring
Pressure and temperature gauges monitor the machine hydraulic system that powers the APC (Automatic Pallet Changer) and certain aspects of the ATC (Automatic Tool Changer). Similar to the coolant monitoring system, the hydraulic system has initial default settings established for the pressure and temperature and will adapt over time to the trends that are analyzed through the software. These indicators will point to impending issues such as a clogged heat exchanger or solenoids sticking open and bleeding off.

| Mechanical Systems Monitoring

| Mechanical Systems Monitoring
The position timing of the clockwise and counterclockwise movement of the APC (Automatic Pallet Changer) is monitored to determine if it is operating out of the ordinary. In addition, the position timing of the shifter advance, shifter retract, and clamp of the ATC (Automatic Tool Changer) is observed to indicate potential issues. A view of the overall number of machine tool changes and pallet changes can be provided to inform users of the current "mileage" on these subsystems.

ALERTS AND CONNECTIVITY

There are three levels of connectivity with MHmax that are tailored to the needs of each customer. Makino values privacy and support customers in protecting their data with high security protocols. With this in mind, MHmax is able to push out alerts and provide dashboard viewing based on the customer’s selected connectivity.


Level 1 connectivity provides access and reporting of the data which is viewable at the machine control next to the operator door of the machine. This is available on Pro6 control machines manufactured in recent years. This connectivity level limits data access and the output of MHmax to the machine-level only. It provides easy-to-understand and information-rich displays for the operator and maintenance staff.



Level 2 connectivity is available for all Pro6 control machines and many of the legacy Pro5 control machines. For Pro6 machines, in addition to the benefits of Level 1 access, the company's private network is used to allow authorized employees to view the dashboards and receive alerts via email. With Pro5 machines, access to the dashboards and alerts is only viewable through the company's private network.


The ability to see all machines in a summary view allows maintenance and engineering staff to stay on top of operations from anywhere they have access to the company's network. This graphical summary makes it possible to instantly see the health of machines using red/yellow/green status indicators. This display is fully customizable and can group machines by type, location, or be customized as desired. From this view, the preventative maintenance schedule and status of each machine can be seen—making it easy for maintenance staff to be proactive.
 
Additionally, MHmax provides direct access to the MyMakino portal. Through this portal, there is a digital dashboard full of personalized options including: machine service history, manuals/machine specifications, training and information, preventative maintenance information, and a link to the Makino online parts store.
 




Level 3 connectivity adds the ability to connect to Makino's Technical Support Team via the cloud— with the features of Level 1 and Leve 2 connectivity. This level does not share any critical data with the Makino Tech Support Team and only provides information such as machine model, serial number, and the specific alert.

Makino is then able to proactively reach out and determine what help is needed. For example, when a preventative maintenance item is due and alert is sent to Makino's Service team, they will communicate to determine if Makino's services are needed.
 

Level 3 connectivity also allows access to the dashboards through a mobile device.

SUMMARY

MHmax offers a tailored high-value sensor package paired with Makino's proprietary machine-learning software to monitor key machine functional areas that are critical to the health of the machine. This unique, self-learning capability can gather and analyze thousands of data points to monitor the status of the machine and predict failures before they happen. MHmax reports on health of these four subsystems:
 
  • Mechanical systems
  • Spindle
  • Coolant system
  • Hydraulics system
 
MHmax can automatically send an email or text alert for out-of-spec conditions. With three different levels of connectivity, manufacturers can choose which one is best for the company.