Checking the Health of your Machine
Starrag’s Fingerprint Online technology determines the condition of spindles, axes and other wear parts within minutes…
Starrag’s Fingerprint Online technology 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 10 to 15 minutes, the software program installed on the Starrag machine carries out frequency response and vibration analyses and a circularity test. It also records the current consumption of all processing axes and determines the degree of contamination and wear of the linear measuring systems, counter readings and temperature data. After 24 hours at the latest, the user finds out how their machine is doing. After automated data analysis, they receive a meaningful report with detailed information on the wear status of the primary assemblies, such as 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. The user can now do what previously had to be determined manually on-site by a service technician with the Fingerprint Online software. All Heckert machines delivered since 2021 are already equipped with the program. Older machines built from 2013 onwards can be retrofitted accordingly, provided a Siemens 840D SL Operate CNC controls them. 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. We only use the already integrated sensors and other onboard equipment,” says Marcel Weber, Product Manager of Service at Starrag. 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 via remote access, e-mail, or USB stick.
The assessment 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. On the other hand, regular fingerprint measurements reveal increasing wear, so 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; with its low evaluation costs, it will pay off,” says Marcel Weber.
The results report, which the customer receives no later than the next working day, is informative yet easy to understand. 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 for rectifying faults or maintenance work is provided. Finally, the display in the traffic light colours green, yellow and red helps customers understand the situation at a glance.
However, before the report is sent to the customer, a service employee checks the results 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. The advantages of Fingerprint Online are considerable. The customer receives a quick and meaningful analysis of the wear condition of the primary 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.
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