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IT Retrofitting Tool Breakage Control with Montronix
Retrofitting tool breakage control. Is it possible? With Montronix, no problem! This is how you stop damage before it occurs. Our systems reliably detect breakages and immediately send the signal to stop the machine. This protects spindle, workpiece, and process quality in any production environment.
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When and Why is it Worth Retrofitting Tool Breakage Control?
A breakage often causes damage to workpieces and spindles unnoticed. Without control, the machine continues to produce until the scrap becomes visible. Tool breakage control detects the breakage in milliseconds and immediately stops the process. This ensures quality, avoids series errors, and protects the machine from expensive repairs.
This is How Our Tool Breakage Control Works
Sensors measure vibrations, structure-borne sound, power, or cutting forces during machining. As soon as a signal changes abruptly, the evaluation unit detects the breakage. The system stops machining before parts become unusable.
Typical components for retrofitting are:
- Power sensor PS200-NG: records current and voltage of the drives
- Acoustic sensor BV100: detects high-frequency signals during breakage
- Acceleration sensor Pulse Plus: measures vibrations on spindle or axis
- Force sensor RetroBolt: records cutting forces directly at the tool
- Evaluation unit Spectra ONE: analyzes data and triggers stop
All systems can be retrofitted independently of the control system.
Retrofitting Tool Breakage Control: Our Products at a Glance
This is How Retrofitting Works
Retrofitting tool breakage control is usually straightforward and completed within a few days. First, the appropriate sensors are mounted on the machine. These record all relevant signals during machining.
In the next step, the evaluation unit (e.g. Spectra ONE or Spectra NG) is connected. It analyzes the data in real time and compares it with the reference values from a short learning run.
As soon as a deviation occurs, for example due to a breakage or collision, the system automatically triggers a stop signal. This is passed directly to the machine control.
Thanks to interfaces such as digital I/O, Profibus, or Profinet, integration into almost any CNC machine is possible, regardless of manufacturer or year of manufacture.
Contact us nowRetrofitting Tool Breakage Control: The Advantages with Montronix
Immediate Breakage Detection and Machine Protection
The retrofit reliably detects tool breakages and sends a stop signal to the control system. This reduces damage to workpiece, spindle, and machine and significantly extends service life.
Avoidance of Scrap Parts and Series Errors
After a breakage, the system immediately interrupts machining. This reduces scrap and ensures consistent quality from the first to the last workpiece.
Flexible Integration into Any CNC Machine
The systems work independently of the control system and can be integrated quickly. Even older systems can be retrofitted within a few hours.
Relief for Operating Personnel
The monitoring runs automatically in the background. Operators do not have to carry out visual checks and can concentrate on other tasks.
Areas of Application
- Machining centers: Monitoring of various tools with the appropriate sensor.
- Lathes: Monitoring of force loss in thread cutters and turning tools.
- Transfer lines: Parallel monitoring of multiple spindles.
- Special machines: Solutions for tight installation spaces or special interfaces.
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Would you like to retrofit tool breakage control and protect your production? Then request your individual offer now or get advice.
Send inquiry nowFAQ: Frequently Asked Questions about Retrofitting Tool Breakage Control
How does our system react?
The sensors constantly record changes in force, structure-borne sound, power, or vibration and compare them with the learned setpoints. The system immediately reports deviations to the machine control to stop machining and thus prevent damage to spindles, fixtures, and workpieces. Thanks to the direct connection to the machine control, your production always remains stable and controlled.
Can I integrate tool breakage control into any machine?
Yes, Montronix systems work independently of controls and years of manufacture. They can be integrated into almost any CNC machine, whether modern or older. Integration is via digital inputs and outputs or via Profibus and Profinet. This makes tool breakage control suitable for retrofit projects and mixed machine parks.
Does the staff need special knowledge to operate it?
No, after setup, tool breakage control runs automatically. During a learning run, the system creates reference data and then detects any deviation. Operators receive clear messages on the HMI or PC. Even without in-depth expertise, employees can use the system safely and ensure consistent quality.
Can I test tool breakage control in advance?
Yes, Montronix offers test setups directly in your production. You test the systems with your own workpieces and processes. During the test phase, you see how the sensors detect breakages and how the system reacts immediately. After completion, you take over the installed technology directly into regular operation.