Tool breakage has been one of the key challenges in manufacturing facilities. Tool wear, over usage, and operator error are some of the reasons for tool failure during machining operations. Tool wear occurs naturally and can cause breakage if not changed at the correct intervals. It is common knowledge that tool breakages cost time and money. What are other consequences? They can affect product quality, cause machine downtime, and ultimately hamper your brand image. With so many CNC machine shops competing to find customers, do you want this to happen? If not, you should look to add a reliable CNC tool breakage detection system. This post discusses these tool breakage detection systems in detail, including their technologies and benefits.
Why CNC Tool Breakage Detection Systems Are Important for Your CNC Machine Shop
There is a common misconception that CNC machines never fail and they will bring you good fortune in the long run. It is true that these machines offer high value for investment, but they are like any regular machines that require maintenance and attention. This is where CNC tool breakage detection systems can make a difference. The following pointers will help you understand these devices and their benefits.
There are four types of breakage tool detection technologies – wired, wireless, contact, and non-contact.
Wired technologies do not require huge investments and no regular battery charging or replacements.
Wireless technologies feature batteries and additional hardware. These batteries require regular charging.
Contact technologies feature touch probes and wands that can easily locate the breakage. They make contact with the tool to identify the nature of breakage. These technologies can be ideal for high-speed CNC environments where regular wired technologies or other technologies on this list may not perform.
Non-contact technologies use power, vibration or laser beams to analyze the condition of the broken tool.
Each of these technologies offers some benefits. Most manufacturers use a single technology or some rely on multiple technologies to realize the following benefits of CNC tool breakage detection systems.
- Improved Accuracy:
The tool detection systems help manufacturers identify if the components being machined are accurate or if they are missing some features. This will help them improve the accuracy of the machined product.
- Minimal Scraps:
Broken cutting tools can lead to part damage and scrap. However, detecting a broken tool before running the next tool can eliminate costly scrap and improve productivity.
- Minimal Operator Handling:
The CNC machines are designed for non-stop performance and minimal human intervention. In reality, they require human intervention at times. If the CNC machine shop hasn’t invested in tool breakage detection systems, then CNC machinists need to inspect the workpieces and tools to check their accuracy manually. However, by investing in CNC tool breakage detection systems they can easily minimize human intervention and improve accuracy.
- High Efficiency:
Efficiency is a term that encompasses several aspects, including productivity, time-to-market capabilities, meeting deadlines, and competitive pricing. All the above pointers suggest how CNC tool breakage detection systems contribute to the process and organization-wide efficiency in a CNC machine shop.
In short, it can be rightly said that CNC tool breakage detection systems can fuel your lean manufacturing initiatives. They help reduce scrap parts, optimize the efficiency of your existing CNC investments, minimize downtimes, and improve your brand value.
CNC tool breakage detection systems have gained traction in recent years. You can easily find several systems in different technology categories listed on this website. In addition to technology, you can find these systems in different price ranges. Investing in the right system depends on several factors, such as your technology preference, the type of CNC machines used in your machine shop, your budget, and so on. Quality is one factor that you cannot ignore at any time. Ensure to source your tool breakage system from a trusted manufacturer. BK Mikro and Techa-Check are two such quality tool monitoring systems offered by Techna –Tool. These systems are ideal for monitoring stationary and rotational tools. These CNC tool breakage detection systems have been widely used in CNC machine shops that cater to clients in medical, aerospace, automotive and other industrial sectors. To find the best system for your needs reach out to one of our specialists who can help you choose the proper system for your application.
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