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IT Power Sensor from Montronix
The PS200-NG measures the active power of your spindle and feed drives directly during operation. It immediately detects even the smallest deviations such as tool breakage or material changes. As a compact complete system, the sensor can be quickly integrated.
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Power Sensor PS200-NG: Technical Data
The PS200-NG records current and voltage, calculates the electrical active power from them, and provides this as an analog signal. You connect it to DC motors or to single-phase and three-phase AC drives. It works independently of the control system and is suitable for both new systems and modernized machines.
The PS200-NG Power Sensor:
Technical Features and Application Advantages at a Glance
Note
If you are already using Montronix systems, use the DGM sensor as an amplifier unit. This is particularly suitable for modular integration with older Montronix systems and allows flexible adjustment of signal behavior and amplification.
Product Advantages of Our Power Sensor
- Accurate power measurement
The sensor detects changes in current and voltage from ±0.25 percent and delivers an output signal within 1 microsecond. - Customizable signal processing
You can select amplifications from 1 to 4096 and set filters for each tool precisely to the process. - Wide range of applications
You can monitor DC motors and AC drives with 1 or 3 phases up to 300 amperes nominal current. - Easy retrofit
You connect the sensor directly via a 3-pin M8 connector and integrate it without intervention in the machine control.
Your Benefits When Using Our Power Sensor
1. Detect tool breakage immediately
When a tool breaks, the power consumption of the drive changes abruptly. The PS200-NG detects this change in less than a millisecond and triggers the stop signal. This prevents consequential damage to the spindle or components, as well as expensive rework of your part.
2. Avoid scrap
Unsuitable material or worn tools produce defective parts. The sensor detects such deviations at an early stage and reports them before the machine produces more scrap parts.
3. Plan maintenance proactively
If the feed or spindle draws more current during operation over time, this indicates increasing tool wear. The PS200-NG documents this increase via the power signal and thus provides early indications of necessary maintenance before the tool, component, or spindle is damaged.
4. Increase machine uptime
The sensor detects critical load changes immediately and stops the process before components are damaged. This helps you avoid unplanned downtime due to tool breakage or collision, especially during shifts without experienced personnel or during unattended night operation.
Where the Power Sensor is Used
- Milling and turning centers: The sensor monitors drive power at every tool change. Especially with small cutters or long machining operations, it provides quick feedback in case of overload.
- Multi-spindle machines: The PS200-NG detects power deviations per spindle. This allows you to balance loads and prevent defective parts in series production.
- Retrofit of existing machines: Many older machines do not have integrated monitoring. The PS200-NG can be installed directly in such systems and increases their safety. All without intervention in the control system.
- Automated production lines: During shifts without personnel, the sensor independently detects process deviations. This protects components and prevents series errors in automated processes.
Contact
Would you like to test or use the PS200-NG in your machine? Then write to us. We will check compatibility, advise you personally, and provide you with the system if desired, also as a loan directly in your production.
Send request nowFAQ: Frequently Asked Questions about the Power Sensor
Can I use the power sensor without the Montronix Spectra system?
Yes, that's possible. The PS200-NG provides an analog output signal that you can also evaluate with other systems, e.g., with existing machine monitoring or independent analysis modules. It is important that the receiving system processes the voltage signal correctly. However, if you want to fully use functions such as tool monitoring, curve comparison, or automatic stops, we recommend using Spectra ONE.
How do I set the power sensor for different tools?
In the connected evaluation system, you store individual settings for each tool. There you define the filters and select from up to twelve amplification levels between 1 and 4096. This allows the sensor to adapt precisely to machining operations with high or low power requirements. This flexibility is a great advantage, especially with changing tools or small cutters.
How many sensors do I need per machine?
One sensor per spindle is sufficient in most cases. If your machine has several spindles or independently controlled feed drives, it may make sense to integrate additional sensors. This way you record each drive unit separately and get more precise process data. We are happy to support you in selection and design.
How does the PS200-NG help to avoid production downtime?
The sensor continuously monitors current and voltage and immediately detects any deviation. This means it registers signs of tool breakage, air cuts, or overloaded drives as soon as they occur. Even before the control system reacts, it sends a signal and can stop the process. This prevents consequential damage and avoids long downtimes.
What signals does the PS200-NG provide?
The sensor calculates the current active power of the motor from current and voltage. It outputs this signal as a digital signal, which can be connected directly via the M8 connector to an evaluation unit such as Spectra ONE or to other measuring systems. This allows the process to be monitored precisely and in real time. With the PS200 DGM, you can also integrate the analog voltage signal in the range from minus 10 to plus 10 volts into older systems or directly into your control system.
How do I adapt the PS200-NG to different tools?
You save a separate profile with suitable signal parameters for each tool. This way, the sensor reacts exactly to the expected power consumption for each tool change. Filter and amplification factor can be freely combined. This means you can reliably detect any deviation, even with changing materials or cutter diameters.