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IT Tool Breakage Detection with Montronix Systems
Montronix tool breakage detection identifies tool breakage within a few milliseconds and immediately triggers the stop signal. The goal is to avoid expensive spindle damage, damaged workpieces, and series errors before they occur. The system intervenes faster than any machine control and works continuously in the background, even without operator intervention.
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What does tool breakage detection mean?
Tool breakage detection captures the moment when a tool breaks or fails during machining. Sensors register abrupt changes in vibration, force, or power and pass these on to the evaluation device. This analyzes the data and sends a stop signal to the machine control within a few milliseconds. This prevents costly consequential damage.
What causes tool breakage?
Tool breakage is often the result of avoidable process errors or inadequate machine conditions. Typical causes include:
- Insufficient workpiece clamping, leading to unwanted vibrations or workpiece movement during machining.
- Incorrectly stored tool data, such as wrong length, diameter, or cutting values, leading to overload or incorrect control.
- Unsuitable selection of feed rate or speed, causing the tool to be thermally or mechanically overloaded.
- Material defects in the blank, such as cavities, inclusions, or internal stresses, which can lead to uncontrolled tool failure.
- Worn or damaged tools that are not detected or replaced in time and break during the machining process.
These Components are Offered by Montronix for Tool Breakage Detection
Your Solution with Montronix
Montronix can provide a test setup directly in your machine so you can test tool breakage detection under real conditions. Our team analyzes your application and recommends the right sensor system for your requirements. We support you with integration, even for older machines or mixed systems. If required, we develop special solutions for tight installation spaces, special interfaces, or specific process requirements.
Contact us nowYour Advantages with Our Tool Breakage Detection Solutions
Protection of the machine spindle
The system triggers the stop signal within a few milliseconds. As a result, the spindle usually remains undamaged even if the tool breaks.
Avoidance of scrap parts
After tool breakage, the machining process is stopped immediately. This means you do not continue to produce defective parts and avoid series errors from the outset. If a tap breaks, machining continues until the end of the cycle or a retraction is initiated and then aborted, as after the break part of the tap is still in the workpiece.
Utilization of tool life
The sensors detect the change at breakage exactly at the wear limit. This allows you to use your tools up to their maximum service life and save changeover costs.
Retrofitting existing machines
Montronix systems can be integrated into the control system with minimal intervention. Unlike manufacturer-bound solutions, this is ideal for retrofit and mixed systems.
Relief for operating personnel
After setup, monitoring runs automatically in the background. The system immediately reports deviations and also supports less experienced employees in shift operation.
Areas of Application for Tool Breakage Detection
Montronix systems are suitable for machining centers, lathes, transfer lines, and also for special machines with individual requirements. Typical applications include breakage protection for small cutters at high speed or monitoring multiple spindles in parallel processes.
Don't wait any longer – act proactively!
Would you like to use tool breakage detection in your production and avoid damage? Then request a test setup now or get advice. We will find the right solution for your machine, regardless of age, manufacturer, or control system.
Send inquiry nowFAQ: Frequently Asked Questions about Tool Breakage Detection
How does the system detect tool breakage?
The system measures physical quantities such as vibration, power, or force. Tool breakage causes an abrupt change in these signals. The evaluation unit immediately detects this deviation and sends a stop signal to the machine. This prevents consequential damage right from the start.
Does the system work with all tools?
Yes, Montronix also detects breakage with drills under 2 mm in diameter. The sensors respond to the smallest signal deviations in the process. This means you can protect machining quality even in delicate applications. This applies regardless of tool type, size, or machining strategy.
Can I retrofit the system?
Yes, Montronix systems can be integrated into almost any CNC machine. The sensors only require mechanical installation and electrical connection. The systems work independently of the control system via digital inputs and outputs or via Profibus and Profinet. Commissioning usually takes place within one working day.
What happens after a break is detected?
The system immediately sends a signal to the control. This stops the process immediately or after the current machining cycle or changes the tool, depending on the setting. You avoid scrap and consequential damage. Optionally, the system also documents the event for traceability.
Do I need special knowledge to operate it?
No, after setup the system works automatically. The learning run takes place at the beginning of setup and creates reference data. After that, the system independently detects all deviations. The operating personnel receive clear feedback in the event of a deviation, without constant monitoring.