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IT Drill Breakage Control: What You Need to Know
The drill breakage control from Montronix detects breakages in real time and stops the process in less than a millisecond. Sensors detect any deviation in force or vibration and prevent defective parts from entering further processing.
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This is How Our Drill Breakage Control System Works in Machine Tools
Our drill breakage control can combine several sensor technologies to reliably and quickly detect breakages. It can be integrated into almost any CNC machine, regardless of year of manufacture or control system.
Typical areas of application are CNC drilling centers, machining centers with automatic tool change, series production with small drill diameters, and unmanned operation systems.
1. Detection
The PS200-NG power sensor continuously measures the active power of spindle and feed drives. Alternatively, the Pulse Plus acceleration sensor detects vibrations in three axes or a BV100 Acoustic Emission Sensor detects the breakage signal directly at the spindle or axis unit. All three sensors respond to the smallest deviations in the machining process.
2. Analysis
The Spectra ONE evaluation unit constantly compares the measured values with stored reference data. It detects changes in force or vibration behavior that are typical for a drill breakage. The evaluation runs automatically in the background and does not require manual control. A breakage leads to a signal increase that exceeds the preset limit and thus triggers a message to the machine control.
3. Reaction
As soon as the system detects a breakage, it sends a stop signal to the machine control in less than a millisecond. This immediately stops machining before damaged parts enter further processing.
Technical Components at a Glance
Our Solutions
For drill breakage control, we combine proven sensor technology with intelligent evaluation. The selection of components depends on machine type, tool diameter, and process requirements.
PS200-NG Power Sensor
The PS200-NG records current and voltage of the drives and calculates the actual active power. It detects even the smallest changes from ±0.25 percent and forwards a signal within one microsecond. This response speed makes it ideal for processes where a drill breakage requires immediate action.
Pulse Plus Acceleration Sensor
The Pulse Plus measures vibrations in three axes with a data rate of up to 26,667 values per second. It detects even the smallest changes in vibration behavior that occur with incipient or complete drill breakage. The compact design allows direct attachment to the spindle and provides real-time data.
BV100 Acoustic Sensor
The BV100 uses piezoelectric technology and measures vibrations in the range from 0.1 hertz to 500 kilohertz. It detects high-frequency structure-borne sound that occurs during contact, friction, or tool breakage. The signal runs from the sensor via a cable to the TSVA2 DGM amplifier, which filters it and passes it on to the Spectra electronic unit. There, the evaluation takes place and, if necessary, the automatic reaction. It works independently of the control and is also suitable for retrofitting.
Spectra ONE Evaluation Unit
The Spectra ONE processes the signals from power and acceleration sensors in real time. It compares the current measured values with stored reference data and detects deviations that indicate a breakage. In the event of a deviation, it triggers the defined reaction within a few milliseconds and automatically documents the incident including a timestamp.
Advantages of Our Products for Drill Breakage Control
Early Breakage Detection
The sensors detect changes in force or vibration within a few milliseconds. The Spectra ONE stops the process before the breakage damages further parts or the machine. The system reliably detects breakages even in drills under 3 millimeters.
High Measurement Accuracy
The PS200-NG registers changes from ±0.25 percent in the force curve. The Pulse Plus measures vibrations in three axes with up to 26,667 measured values per second. This data basis detects even minimal deviations during the drilling process.
Flexible Integration
The sensors can be mounted on spindles, axis units, or machine tables. Integration is via digital inputs and outputs or fieldbus without intervention in the machine control. Installation and commissioning usually take only a few hours.
Evaluable Measurement Data
The system stores all recorded values and displays them at any time on the HMI or PC. Users can thus identify the exact cause of a drill breakage. The data supports process adjustments and prevents repeated failures.
This is How Your Operation Benefits in Everyday Life
- Scrap control: The system stops the process immediately after a breakage and prevents defective parts from entering further processing.
- Machine protection: Breakage detection interrupts machining before the breakage damages the spindle or fixtures.
- Tool utilization: Monitoring uses each drill up to the actual end of its service life and only replaces it then.
- Production security: The production process remains stable because unplanned stops due to breakages are avoided.
- Maintenance planning: Recorded breakage events show when targeted maintenance is useful.
- Relief for personnel: Monitoring replaces manual visual checks and reduces operator errors.
Request Drill Breakage Control Now
Prevent scrap, protect machines, and secure your production. Request your offer for Montronix drill breakage control now and use a solution that reacts in less than a millisecond.
Send inquiry nowFAQ: Frequently Asked Questions about Drill Breakage Control
What is drill breakage control and why is it crucial?
Drill breakage control is the automatic detection of a tool breakage during drilling. It prevents defective workpieces from entering further processing. In addition, the technology protects machines from consequential damage and significantly reduces rework costs. Especially in series production and unmanned operation, it is a crucial factor for quality assurance and process reliability.
How fast does the system react in the event of a breakage?
The sensors register changes in force or vibration data. The system detects even the smallest drills and thus also secures fine machining. This reduces material loss and protects the entire system.
Which sensors are suitable for drill breakage control?
For breakage detection, the PS200-NG power sensor, the BV100 acoustic sensor, and the Pulse Plus acceleration sensor are used. The PS200-NG detects minimal changes in the force curve, the BV100 detects a high-frequency signal caused by the breakage, while the Pulse Plus measures vibrations in three axes. The Spectra ONE evaluation unit analyzes the data and immediately triggers the stored reaction as soon as a breakage is detected.