The Techna-Check® model TC 6400 is a Tool Monitoring system designed to use our PWM-TTBUS 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 setrange.
6400 features include:
- Built in 8” color display and membrane keyboard
- Monitors 1-64 tools or cutting processes per motor
- Up to 8 motors can be connected to a single system
- Available sensors PWM350T, PWM3100T, VM100T, IO100T
- Parameter setup is done through the front plate of the unit
- Panel door mounted or custom enclosure available
- Independent limits for Break, Blunt, Missing and Idle supervision
- Curve enveloping feature for limits
- On board data collection
- Optional Profibus and Ethernet available
- Touch Point limit used for grinding and balancing machines
- Password protected
Principle of Operation
The 6400 interfaces to the machine control and is given a 24vdc signal from the machine to tell the unit when to start monitoring. The signal also can be given via Profibus. The 6400 monitors up to 64 tools or cutting profiles per motor. The 6400 can be equipped to monitor up to 8 different motors, each capable of up to 64 tools or cutting profiles. The tool selection is done via 24vdc binary inputs which are typically given using M-codes or a custom macro or by using Profibus.
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.