Techna-Check® model TC101 is a Tool Monitoring system designed
to use our PWM series power transducers to measure true power
on a machine spindle or axis motor. It can be used on standard motors,
AC servo motors and variable frequency drives. The Techna-Check
determines if there is a Broken, Dull or Missing tool. The system
also has the capability to interface with an accelerometer to measure
vibration on a spindle or fixture and verify it is within a set
Unique features include:
Monitors 1 tool or process
Parameter setup done through included Toolmon software or
via the key pad on the face of the unit.
RS232 for connection to Toolmon software
Capable of networking up to 24 units back to a single PC using RS485 and Toolmon software for data collection
Panel door mounted
Independent limits for Break, Blunt, Missing and Idle supervision
Touch Point limit used for grinding and balancing machines
Principle of Operation:
The TC101 interfaces to the machine control and is given a 24vdc signal from the machine to tell the unit when to start monitoring. The TC101 monitors a single cutting profile or tool on one motor of a machine.
Once the unit has been told to monitor, the system will measure the power that is used just to turn the spindle; this is labeled as the idle consumption (fig. 1). High and low limits can be set for the idle power to determine if a belt has broken or bearings are going bad in the spindle.
The unit then learns the amount of power it takes to cut the material (labeled as measurement in fig. 1). As a tool becomes blunt (dull) the tool will begin to require more power to complete a machining cycle. When the tool breaks a short energy peak or spike is created and if no tool is present or the part has already been cut, the power consumption drops back to zero. If any of these situations occurs the Techna-Check will output a fault which will immediately stop the machine.
Each of these parameters is independent of each other and different limits can be set for each one, allowing for various monitoring scenarios. Limits can be set based off the peaks of the profile or off the area under the curve. Typically a tool's parameters can be set after just a few machining cycles making the system very easy to use and quick to setup.
Another parameter which is available is Touch Point. This is used in grinding and balancing applications where the tool is fed into the part at a rapid rate. As soon as a rise above idle power is detected the system outputs a signal telling the machine control to slow the feed rate of the machine.