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Sensors&Applications
MachineTools
MorePrecision
Sensorsandmeasuringsystemsformachinetools
Modernmachinetoolscomprisenumeroussensors.Compactdesign,longevityandhigheconomicefficiencyaremajorrequirementsthatsensorsshouldmeet.
Micro-Epsilonoffersacomprehensiveproductrangeandsensors,whichareintegratedintothemachinetool.Theportfolioincludesstandardsensorsfordisplacementandpositionmeasurements,aswellasOEMsolutionsforlargevolumes.
eddyNCDTSGS
Sensorsystemdevelopedformeasuringthethermalextensionofmillingspindles
Measuringrangeof500µmResolutionof0.5µm
Hightemperaturerange
wireSENSOR
Robustdraw-wiresensorsforpositionmeasurements
Idealfordifficult-to-accesspositionsHighoperationalsafety&longservicelifeAnaloganddigitaloutputs
induSENSORLVPInductivedisplacementsensorstodetecttheclampingstroke
LinearpositiondetectionwithhighaccuracyHightemperaturestability
Robustandcompactdesign
optoNCDT1420
Compactlaserdisplacementsensor
forhighspeed,precisionmeasurements
Non-contactmeasurementswithlargemeasuringrangesfrom10mmto500mm
HighmeasuringratesfordynamicmeasurementsCompactdesignandeasytoinstall
Monitoring
lengthexpansion
eddyNCDTSGS
Cost-optimizeddesign
Miniaturesensordesign
Miniaturecontroller
Sensorcanbecompletelyintegratedintothespindle
Forferromagneticandnon-ferromagneticmaterials
Sensorwithintegratedtemperaturemeasurement
Thecontrollercanbeintegra-tedintothespindleorflange
mountedontothehousing.
Typicalinstallationscenario:
Measuringonalabyrinth-ring
Measuringthermallengthexpansionofspindles
TheSGS4701displacementmeasuringsystem(SpindleGrowthSystem)isdevelopedspecificallyforhighspeedmillingmachineapplications.Duetohighmachiningspeedsandtheheatgene-rated,thelinearthermalexpansionofthespindleintheprecisionmachinetoolmusttobecompensatedforinordertokeepthetoolinadefinedpositionatalltimes.TheSGSsensormeasuresthethermalandcentrifugalforceexpansionofthespindle.Thesemea-surementvaluesarefedintotheCNCmachinetoolascorrectionalvalues,compensatingforanypositioningerrors.
TheSGS4701operatesontheeddycurrentmeasuringprinciple.Thisnon-contactmeasurementmethodiswear-free.Furthermore,themeasurementprocedureisresistanttodisturbancessuchasheat,dustandoil.
Systemdesign
TheSGS4701consistsofasensor,asensorcableandacontroller,factorycalibratedforferromagneticandnon-ferromagneticmeasurementobjects.Twominiaturesensorsenableittobeinstalleddirectlyinthespindle,wherethemeasurementstakeplace,typicallyonthelabyrinth-ringofthespindle.Aswellasmeasuringlinearthermalexpansion,thetemperatureofthesensorisalsodetectedandoutput.Thecompactcontrollercanbeinstalledonthespindlehousingviaaflangeordirectlyinthespindle.
Monitoring
theclampingpositionoftools
Today,modernhigh-performancemachinetoolsachieveaccuraciesinthemicrometerrange.Realizingtheselevelsofprecisionrequiresallcomponentstobeperfectlymatched-fromthedrivetothereleasedeviceviathetoolclamptothetoolitself.
Sincemostofthecomponentsarepermanentlyinstalledonthemachine,thehighestprecisioncanonlybeachievedifthesewereinstalledcorrectly.Onlythetoolischangedwitheachnewopera-tionandsocancausecriticaldeviations.
Particularattentionshouldthereforebepaidtothecorrectclampingofthetoolintheholder.Inanycase,itneedstobedetectedwhetherthetooliscorrectlyseated.Whenthepositionofthetoolchanges,thismayresultinpoormachiningquality,whichwouldinturnleadtoexpensiveworkpiecesthatneedtobescrapped.Ifthetoolistilted,itcouldbecomelooseduetothehighrotationalspeedsandcauseacollisionwithothermachinecomponents.
Often,initiatorsandswitchingrings,whichprovideaswitchingsignal,areusedtomonitortheclampingposition.However,theserequirecomplexadjustmentandsetup.AnalogsensorsfromtheMicro-EpsilonLVPseriesoffersignificantimprovements.Thecylindricalsensorisintegratedintothereleasedeviceanddirectlymeasurestheclampingstrokeofthedrawbar.Onthedrawbar,aringisfastened,whichactsasthetargetforthesensor.
TheLVPsensorcanbeuniversallyusedwiththemostvariedtypesoftoolduetoanextremelycompactsensordesign.Thesensorsuppliesananalogsignalaccordingtothestrokemotionofthedrawbarwhenclampingthetool.Consequently,continuousmonitoringispossiblewithouttheswitchingpointhavingtobelaboriouslysetmechanically.
Theminiaturizedsensorelectronicunitcaneitherbeaccommodatedatthepointofmeasurementorinthecontrolcabinet.Thankstoitshighaccuracy,theLVPsensorcontributessignificantlytomeetingtheeverincreasingdemandsonmachinetoolprecisionandavailability.
Pos.3ClampingcolletwithouttoolPos.2Toolisclamped
Pos.1Toolisejected
induSENSORLVP
Shortsensordesignwithalargemeasuringrange(25mm)
Compactsensorforeasyintegration
Non-contactandwear-freemeasuringprinciple
Noadjustmentnecessary
Highresolution
Tailstockposition
wireSENSOR
Robustdraw-wiredisplacementsensors
Displacementandpositionmeasurementswithmeasuringrangesupto30m
Analoganddigitaloutputs
Flexiblemeasuringwire,idealfordifficult-to-accesspositions
Compactdesignforintegrationintoconfinedspaces
Positionmeasurementofthetailstock
Thetailstockisanimportantpartofalatheormillingmachine.Thetailstockisusedtosupportlongworkpiecesbymeansofacenter,whichcatchesinthecenterholeonthefrontsideoftheworkpiece.
Inordertodetectthecentertip,compactdraw-wiresensorsfromMicro-Epsilonareused.Themeasuringwireisconnectedtothecentertipandmeasuresthedisplacementofthetailstock.
Compactdraw-wiresensors
Draw-wiresensorsofferoutstandingprice/performanceratioscombinedwithcompactdesigns.Duetotheirminiaturedesign,thesensorscanalsobeintegratedintorestrictedinstallationspaces.Furthermore,themeasuringwirecanalsobeguidedintodifficult-to-accessareasandcanbedeviated.Typically,sensorswithmeasuringrangesfrom300mmto2100mmareused.Dependingonrequirements,largermeasuringrangescanbeselected.
Basedonhigh-qualitycomponents,draw-wiresensorsfromMicro-Epsilonofferalongservicelife-evenincontinuoususeunderharshindustrialconditions.Eitherarobustplasticoraluminumhousingprotectsthesensorsfromexternalinfluences.Dependingonthesignalconnection,differentoutputtypesareavailable.
Byusingdeflectionrollers,themeasuringwirecanalsoberoutedintohard-to-reachinstallationspaces.
Measuringtoolholders
Measuringtoolholdersinthemagazine
Modernmachinetoolshavecomplexmagazineswithvarioustoolsthatareautomaticallypickedupbythemachine.Inorderforthesetoolstobeaccuratelypickedup,thetoolholdersmustbepreciselypositioned.
Tocheckthepositionofthetoolholders,optoNCDT1420lasersensorsareused,whichmeasurethemetallicholdersfromaboveandfromtheside.Thesesmartlasersensorsstandoutduetotheirhighmeasuringrateswhileprovidingprecisemeasurementvalues,despitestronglyreflecting,metallicsurfaces.
optoNCDT1420
Compactlasertriangulationdisplacementsensorforhighspeed,precisionmeasurements
Non-contactdisplacementanddistancemeasurementswithlargemeasuringrangesfrom10mmto500mm
Highaccuracy
Highmeasuringratefordynamicmeasurements
Compactdesignandeasytoinstall
Positionmeasurementinthe
zeropointclampingsystem
mainSENSOR
Magneto-inductivesensorsfornon-contactandlineardisplacementmeasurements
Selectablemeasuringrangesupto55mm
Highbasicsensitivityandtemperaturestability
Non-contactandwear-free
Availableinanyquantity
Magneto-inductivesensorsareavailableindifferentvariants.Fromthesolidstainless-steelvarianttothecompactPCBmodel,theproductrangeoffersasuitablemodelforeachoperationalsite.Themagnetdeterminesthemeasuringrange-thelargerthemagnet,thelargerthemeasuringrange(max.55mm).
Positionmeasurementinthezeropointclampingsystem
Inmodernmachinetools,zeropointclampingsystemsensurereproduciblepositioningoftheworkpieces,clampingstationsandworkpiececarriers.Thecarriersarepositionedviaclampingboltsandthenlocked.Exactandreproduciblepositioningisacrucialfactorforthesafetyandthequalityoftheprocessingwork.
Magneto-inductivedisplacementsensorsfromMicro-Epsilonmeasurethepositionoftheclampingcylinder.Insertingtheclampingboltintothecylindercausesthelockingunittomove.Thepositionofthelockprovidesinformationonwhethertheclampingboltfitsaccurately.Amagnetattachedtothelockactsasameasurementobjectforthesensor.Thesensorpermanentlymeasuresthemagnet’smovementandtransmitsthistothecontrolsystem.
Miniaturizationandcostefficiencyaretwocentralrequirementsthatsensorsinclampingsystemsmustfulfill.Magneto-inductivesensorsfromMicro-EpsilonareavailableinminiaturesizeorasaPCBsolutionforhighquantities.Particularlyinserialapplications,themainSENSORseriesimpresseswithanexcellentprice/performanceratio.
Lockingunit
Lockingunit
Magnet
Sensor
(plastichousing)
Magnet
Clampingbolt
PCBsensor
Measuringthespindlerunout
eddyNCDT3005
Inductivesensors(eddycurrent)fordisplacement,distance,position
Non-contactdisplacementanddistancemeasurementswithmeasuringrangesfrom1to6mm(customizable)
Highfrequencyresponsefordynamicmeasurements
Insensitivetofluctuatingtemperatures
Pressure-resistantmodelsupto10bar(alsoavailableforhigherpressuresascustomer-specificsensors)
Resistanttooil,dust&dirt
Concentricity/Shaftrunoutofspindles
Manyfactorsinfluencetheprocessingqualityofmachinetools.Particularlyinhigh-frequencyspindles,theaccurateconcentricityorshaftrunoutofthetoolplayadecisiverole.
Non-contact,inductivedisplacementsensorsfromMicro-Epsilonareusedforcontinuousmonitoringofconcentricityorshaftrunout.Basedontheeddycurrenttechnology,thesesensorsprovideextremelyhighresolutionevenwhenoilanddirtcontaminatetheinstallationspace.Thisishowthemeasurementaccuracyinthemicrometerrangeisachieved.Thehighfrequencyresponseevenenablesthemonitoringofhigh-frequencyspindleswithrotationalspeeds>120,000rpm.
ThemeasurementprocessinvolvestheeddyNCDT3005measuringsystem,whichisideallysuitedtonon-ferromagnetictargets.Themeasuringsystemperformsanon-contactmeasurementontoanaluminumringwhic
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