High-speed Tool Breakage Detection System

Marposs S.p.A.’s Tool Breakage Detector (TBD) is a time-saving laser-based solution for tool breakage detection in a machine. TBD on milling machines and machining centres help to keep the process under control, thanks to a very short tool checking cycle. Fast and reliable detection achieved by the TBD reduces production time and avoids expensive work-pieces scrap due to wrong cutting process by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table.

Switching the power to the maximum gets the detector to recognize a tool placed at a longer distance (up to 2 m), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, a user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting it on “Hi Filter” makes the software of the TBD more restrictive in order to give a more reliable response. On the other hand, choosing “Low Filter” helps it respond in a faster way, as the filter is less severe.

It is also possible to choose the appropriate range of spindle speed up to 5000 rpm.

The new TBD HS

Marposs S.p.A. has recently introduced a new programmable system, TBD High Speed (HS), for non-contact checking hi-speed tools, particularly committed to those applica-tions where there is the need for hi-speed spindles, up to 80,000 rpm

Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. On selecting “Quick Recognition”, the tool checking is performed for 10,000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1,000 rpm and its multiples or 10,000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD.High spindle speeds and small tool dimensions lead to the need for a fine adjustment for positioning the TBD HS in a very precise way. Once TBD is installed and the tool approximately pointed, now it is even more quick and simple to optimize the laser beam and find the checking position.