In CNC machining, a single error can bring production to a standstill for hours on end. All it takes is a collision between the tool and the workpiece, the chuck or a machine component, and downtime, repairs and frantic attempts to figure out what actually went wrong begin. Protect MyMachine/3D Twin, a machine protection system based on a digital twin, is designed precisely for such situations.
This solution uses a virtual model of the machine tool and continuously protects structural components and those involved in the machining process on the actual machine. Not only are the machine’s components protected, but also the fixtures, tools and the workpiece itself, even during material removal. The result is simple: fewer unplanned downtimes and fewer costly repairs. On top of that, there is a lower risk of dimensional errors, which can only become apparent once machining is complete.
Real-time protection for CNC machine tools
How does this work in practice? The system monitors all static and moving components as 3D objects within the machine’s working space. It takes into account the actual kinematics and current axis positions. Based on this data, it performs a 3D simulation of the machining process. Potential collisions are calculated in advance, and if the system detects a risk, it halts machining before any damage occurs.
Data synchronisation plays a major role. Information on tool geometry or zero-point offsets is retrieved directly from the NC and updated in real time within the system. If the measuring probe changes the active zero point offset, the digital model takes this into account immediately. As a result, the simulation is not based on ‘yesterday’s’ data, but on what is actually set on the machine.
The system also allows variable safety zones to be defined. The user can create and save models of tools with holders, workpieces or clamping devices in the library. All safety features are based on a model of the actual machine, taking collision groups into account. This provides great flexibility for various production setups.
It is also worth noting that the calculations involved in collision control are performed on a separate industrial computer. This ensures that the NCU is not overloaded, and the machining process itself runs smoothly and safely.
In day-to-day operations, the greatest advantage is that errors related to setup or programming can be detected on the 3D model before they cause actual damage. Even in well-organised production, operator errors, differences in tool lengths or reference points can occur. Without real-time protection, this often results in either a collision or excessive caution and prolonged process implementation times. Here, the system assumes part of this risk.
An additional advantage is the ease of data exchange through rapid integration with CAM systems. Configurations can be saved and transferred to other machines, which simplifies maintenance and reduces the time needed to set up a new workstation.
Most importantly, however, the anti-collision protection works in every operating mode. Whether the machine is running a programme or the operator is making manual movements, the system remains constantly vigilant. As a result, the digital twin ceases to be merely a visualisation and becomes a real safeguard for production.
