Built-in Type ATC Run-Out Detection System

Aluminum high-speed cutting process monitoring device

  • Sudden machining defects.
  • Aren't they being caused by chips in the tool chuck?

Features

How do chips in the tool chuck cause defects?

In an ATC machining center, defects can be generated during ATC when chips get into the space between the tool taper and the main spindle.
For years, machining centers have looked for a solution to this problem, which is particularly prevalent during high-speed cutting of aluminum.

Monitoring high-speed cutting of aluminum

Because of shorter processing times, reductions in the amounts of coolants, and other aluminum process demands, the frequency of chips getting into the tool taper during ATC is increasing. During high-speed cutting of aluminum in particular, a measurement instrument must be able to detect 100% of chip invasion into the tool taper, so defects are not generated.

0.3 second measuring time

An eddy-current sensor allows measurement in a mere 0.3 seconds (at 600 rpm).
Since the measuring tool is selectable, measuring time is not affected by the cycle time. A dedicated run-out detection system algorithm (patent pending) calculates true run-out for detection capability that cannot be achieved by commercially available eddy sensors. All of this means that the system delivers precise, reliable detection in an automated line.

Low cost, integrated type

By connecting a PC to this device, you can set up parameters and collect measurement data. This device need not be connected to a PC when performing regular measurement. All NC communication has been incorporated in to the OK/NG functions, which greatly reduces cost. Because of all of this, this system is being adopted by many machine tool manufacturers.


Low cost, integrated type

Specifications

Specifications

 
Type Controller AT50361
φ 5 sensor E-DT-ED10 (cable 10 m)
Sensor installation range 1.0±0.1mm from tool holder flange surface
Measuring range 1.0±0.2mm from tool holder flange surface
Tool registration 32 max
Acceptable tools BT30, BT40, BT50, HSK63A, etc.
Performance Display unit 0.5 µm
Repeatability 3 μm (2σ = 1.5 μm) *Using our master tool holder (BT40)
Tool rotation Speed 120, 600, 1200 rot/min
Cycle time 0.3 s (rotation speed 600 rot/min, without retries)
Using environment Temperature 0 to 40 ℃
Vibration resistance 3.66 G max. (x, y, z-axis directions) JIS C 60068-2-6
*Sweep 25 min at 10 to 15Hz (5 min per sweep)
Shock resistance Sensor head: 50 G max. (x, y, z-axis directions, 10 times)
Controller: 20 G max. (x, y, z-axis directions, 10 times)
Waterproof standard IP67 (Sensor Head)
*Do not expose controller to water , oil or other liquids.
Power requirements Nominal voltage DC24V±10%
Nominal voltage 14 W
Windows application operating environment and conditions
Compatible machine PC with Windows 7 (32/64 bit),
Windows 10 (32/64 bit)
Physical Memory 128 MB or more (Windows 7 (32bit))
1 GB or more (Windows 7 (32/64 bit), Windows 10 (32/64 bit))
Disk space 100 MB or more abailable disk space.
OS Windows 7 (32/64 bit), Windows 10 (32/64 bit)
*Windows is a trademark of Microsoft Corporation in the United States.
Interface One of RS-232C port COM1to COM16 is used.

Standard system

 
Product code Product name Model Remarks
991012 ATC Runout Detection System AT50361
E-DT-ED10
Details: Controller, Φ 5 Sensor head 10 m, I/O cable 10 m, Power cable 10 m, Windows application CD, Operation manual (Japanese/English) per 2 copies, Inspection certificate 1 copy

Display unit

 
Product code Product name Model Remarks
4220520 Display unit set AT50366
JPN-ENG
Language: Japanese/English
Details: Display unit, Power cable 10 m, USB memory 4 GB, Operation manual (Japanese/English) per 1 copy, Inspection certificate 1 copy
4220611 Display unit set AT50366K
KOR-ENG
Language: Korean/English
Details: Display unit, Power cable 10 m, USB memory 4 GB, Operation manual (Korean/English) per 1 copy, Inspection certificate 1 copy
4220631 Display unit set AT50366C
CHIN-ENG
Language: Chinese/English
Details: Display unit, Power cable 10 m, USB memory 4 GB, Operation manual (Chinese/English) per 1 copy, Inspection certificate 1 copy

System configuration

System configuration

Overview

Controller

Controller

Sensor head

Sensor head

Display unit

Display unit

Precautions for sensor head mounting

  1. Do not extend or cut the sensor head cable. Prepare a cable in an appropriate length by confirming the cable layout. Use a two-way device when cutting the cable for connecting the terminal.
  2. Although the sensor head is tested in accordance with waterproofing structure (Protective class IP 67) and anti-coolant characteristic test, it does not mean that it is guaranteed for all type of coolant.
  3. Replaceable “Protective cap” is equipped in the sensor head for abrasion protection against chips. Do not remove this “Protective cap” when the system is operating.
  4. Use protective pipe for sensor head cables to protect from chips.
    Maintain the cable bending more than R>35 mm (1.4” approx).
  5. Do not use the sensor head cable as it is wound.

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