The need to ramp up machine tool productivity results in the use of ever-increasing cutting speeds or axis-movement speeds. This in turn increases the risk of serious collisions between tools and workpieces mainly attributable to errors (digital control programming errors; erroneous workpiece positioning; manual movements), in addition to greater force being exerted on spindles secondary to micro-shocks that are difficult to avoid, but may occur frequently when tools and workpieces come into contact with each other.
In the former scenario, an uncontrolled shock can seriously damage the workpiece or the machine tool and result in repair costs. In the latter scenario, micro-shocks can cause brinelling (indentation of a hard surface) of spindle bearings, which can significantly increase wear and tear.
It is therefore essential to monitor collisions so as to avoid potentially catastrophic consequences, and in order to keep possible effects of micro-collisions on spindle wear and tear within reasonable bounds.
SeTAC is the ideal solution for implementation of this type of continuous monitoring. The triaxial sensors detect collisions in any direction, while the solution’s special internal algorithm allows the system to clearly distinguish between collisions on the one hand, and normal machine-tool movements and normal vibration phenomena that are typical of machining processes, on the other. The system automatically logs all collisions in the internal memory, making this data available for machining-process severity assessments, and allowing you to optimize and evaluate the impact of these events on bearing wear. The system also generates an extremely rapid relay alert with less than 1 ms of response time, which can be utilized to shut down the machine instantaneously.