Machine, how are you?

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customer-service

Machine, how are you?

Fingerprint Online determines the condition of spindles, axes and other wear parts within minutes – without a service technician on site and with a meaningful evaluation in less than 24 hours.

If errors occur in the production process or unclear damage situations arise, these must be analysed as quickly as possible. This is a task for Fingerprint Online. In just ten to 15 minutes, the software programme installed on the machine carries out frequency response and vibration analyses as well as a circularity test. It also records the current consumption of all processing axes, determines the degree of contamination and wear of the linear measuring systems, counter readings and temperature data. And after 24 hours at the latest, the user finds out how their machine is actually doing. After automated data analysis, they then receive a meaningful report with detailed information on the wear status of the main assemblies, i.e. the axes, drives, bearings and, of course, the spindle.

It’s no wonder that Fingerprint Online, which Starrag has been offering since 2021, is so popular. What previously had to be determined manually on site by a service technician can now be done by the user with the Fingerprint Online software. All Heckert machines delivered since then are already equipped with the program. Older machines built from 2013 onwards can be retrofitted accordingly, provided they are controlled by a Siemens 840D sl Operate CNC. Fingerprint Online has also been available for Fanuc controllers since 2024. Furthermore, the software was rolled out to the Starrag machines at the Rorschacherberg, Vuadens and Bielefeld sites.

“No additional measuring device is required for Fingerprint Online,” says Marcel Weber, Product Manager Service at Starrag. “We only use the sensors that are already integrated and other on-board equipment.” They deliver data that is only a few megabytes in size at the end of the measurement process. The package must be sent to Starrag for evaluation – either via remote access, by e-mail or with a USB stick. The evaluation is automated. Developer Leon Madalschek explains: “We assess the recorded values and compare them with previous measurement results. We have developed algorithms to analyse the data and fed them with knowledge from our experts.

This gives us a consistently high evaluation quality.” Fellow developer Denny Auerswald adds: “We are constantly developing the algorithms further, incorporating the latest findings and suggestions from all locations so that our customers can derive as much benefit as possible from the Fingerprint service.” On the one hand, the customer benefits from the rapid assessment of the machine’s condition mentioned above. On the other hand, regular fingerprint measurements reveal increasing wear, so that unplanned machine downtime can be avoided by implementing predictive maintenance measures at an early stage. “We recommend carrying out the Fingerprint Online service every three to six months,” says Marcel Weber. “With the low evaluation costs, it will definitely pay off.” The results report, which the customer receives no later than the next working day, is informative yet easy to understand.

The advantages of Fingerprint Online are considerable:

The customer receives a quick and meaningful analysis of the wear condition of the main assemblies of their machine at a low cost and quickly. It can save costs for maintenance and resources and prevent unplanned machine downtime due to wear.

The Fingerprint Online supports the user in increasing machine availability and productivity and ultimately reducing workpiece costs.

Marcel Weber (middle), Product Manager Service and his Team: “We are constantly developing the algorithms further, incorporating the latest findings and suggestions from all locations so that our customers can derive as much benefit as possible from the Fingerprint service.”

It displays the results – sorted by measurements – in various forms: A diagram provides the experienced technician with in-depth information. The status of the respective module is described in plain text and, if necessary, a suggestion is made for rectifying faults or for maintenance work. Finally, the display in the traffic light colours green, yellow and red helps you to understand the situation at a glance.

However, before the report is sent to the customer, a service employee checks the results in order to make personal contact if necessary – if urgent work needs to be carried out or if it is advisable to keep a spare part in stock.