Technology

In the world of machining with large tools, monitoring spindle load can be used as a means of detecting breakage. If there is a fluctuation or drop-off in the current, then the operator knows that the tool might be broken. Unfortunately, the benefits of this “Tool Detection” process are limited because it is used only as a means of checking tools and reporting possible breakage without systematically replacing the broken tool. So, the best that a manufacturer can hope for is that the machine will shut off and prevent additional damage to costly blanks. Still, production time is lost — and if the tool breakage occurs early in a “lights-out” overnight shift, it can significantly impact schedules and revenue. Furthermore, this method doesn’t work when using micro tooling because the load involved is sometimes so small that the fluctuation in power usage doesn’t even register.

But, DATRON’s Automatic Tool Management System™ is made up of three separate components working synergistically — the tool checker, the tool changer, and the software. The tool checker is a mechanical sensor that measures tool length and detects the broken tool. The tool changer is a rack or tray that has space for spare tools and sockets where the machine places broken tools before picking up a replacement. Operators can stock the rack with spare tools, thereby having a ready supply should tools break during “lights out” operation. The software is a macro program that can be set up to run a tool check after executing a number of lines of code. For example, a tool check macro can initiate a check after every 500 lines of code by employing an “if/then” statement such as, “Measure this tool; if the length is shorter than the parameter (listed in the software’s tool database), then change the tool.”