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Aluminum high-speed cutting process monitoring device ˙ Monitoring high-speed cutting of aluminum Because of shorter processing times, reductions in the amounts of coolants, and other aluminum process demands, the frequency of chips getting into the tool taper during ATC is increasing. During high-speed cutting of aluminum in particular, a measure- ment instrument must be able to detect 100% of chip invasion into the tool taper, so defects are not generated. ˙ 0.3 second measuring time An eddy-current sensor allows measurement in a mere 0.3 seconds (at 600 rpm). Since the measuring tool is selectable, measuring time is not affected by the cycle time. A dedicated run-out detection system algorithm (patent pending) calculates true run-out for detection capability that cannot be achieved by commercially available eddy sensors. All of this means that the system delivers precise, reliable detection in an automated line. ˙ Low cost, integrated type By connecting a PC to this device, you can set up parameters and collect measurement data. This device need not be connected to a PC when performing regular measurement. All NC communication has been incor- porated in to the OK/NG functions, which greatly reduces cost. Because of all of this, this system is being adopted by many machine tool manu- facturers. How do chips in the tool chuck cause defects? In an ATC machining center, defects can be generated during ATC when chips get into the space between the tool taper and the main spindle. For years, machining centers have looked for a solution to this problem, which is particularly prevalent during high-speed cutting of aluminum. Sudden machining defects. Aren’t they being caused by chips in the tool chuck? Chips
126 Laser Interferometers/Built-In Type Measuring Instruments
Laser Interferometers/Built-In Type Measuring Instruments Built-In Type ATC Run-Out Detection System ʫ ʫ ʫ Built-In Type ATC Run-Out Detection System
Laser Interferometers/Built-In Type Measuring Instruments Specifications Product Code Options Product Name Model Qty 4206889 4206890 4206865 4206868 4206870 4206876 4206877 4206878 4206879 Built-in type ATC run-out detection system П5 sensor Built-in type ATC run-out detection system П10 sensor I/O cable 15 m Power cable 15 m Casing tube 2.8 m Sensor connection pressure terminals R 2-3S (100 ea.) Sensor protection П5 (10 ea.) Sensor protection caps П10 (10 ea.) Protection cap gasket AT50316-05C-011 AT50316-1035C AT50304 AT50305 П5, cable length: 3m Or П10, cable length: 3.5m Eddy-current sensor controller Power cable 10m DC 24V power supply, 50W ATC Run-out Detection System Windows application I/O cable 10m NC RS-232C PC Eddy-current sensor head Items enclosed in dotted lines are provided by the end user. ˎ Windows application provided as standard Model П5 sensor AT50316-05C-021 П10 sensor AT50316-1035C Sensor instal- lation limit П5 sensor 1.1 ʶ0.1mm from tool holder flange surface П10 sensor 1.1 ʶ0.1mm from tool holder flange surface Measuring range П5 sensor 1.1 ʶ0.2mm from tool holder flange surface П10 sensor 1.1 ʶ0.2mm from tool holder flange surface Tool registrations 32 max. Available tools BT30, BT40, BT50, HSK63, etc. Performance Display unit 0.5Жm Repeatability 3Жm or less * Using our master tool holder (BT40) Tool rotation speed 120,600 rot/min Cycle time 0.3s (rotation speed 600 rot/min, without retries) Usage environment Temperature 0 to 40°C Vibration resistance 3.66 G max. (x, y, z-axis directions) Shock resistance Sensor head: 50G max. (r, z directions, 10 times) Amplifier head: 20 G max. (x, y, z directions, 10 times) Waterproof standard IP67 (Sensor Head) *Do not allow water, oil or other liquids to splash amplifier unit. Power requirements Rated voltage DC24Vʶ10% Rated power 14W Windows application operating environment and conditions Compatible machine PC running Windows XP RAM 64MB or more Disk space At least 100MB of free disk space is required. OS Windows XP * Windows XP is a trademark of Microsoft Corporation of the United States. Interface One of RS-232C port COM1, COM2, COM3 and COM4 is used.
128 Laser Interferometers/Built-In Type Measuring Instruments
2 155 (14.8) 152 (171.8) (25) (42) 4-M6, depth 8.5ɹ (tapped for mounting) (18)11816 1678(16) П10 110 513 A ʪ*OTUBMMBUJPO1SFDBVUJPOTʫ "MMPXBUMFBTUNNPSTQBDFBCPWFUIFEFWJDF "MMPXBUMFBTUNNPSTQBDFCFIJOEUIFEFWJDF -JNJUUIFTDSFXJOEFQUIPGUIFNPVOUJOHTDSFXT . UPNN *OTUBMMUIFEFWJDFBUBMPDBUJPOXIFSFJUXJMMOPUCFTQMBTIFE XJUIDPPMBOUPSPUIFSMJRVJET SFDPNNFOEFEQSPUFDUJWFIPVTJOH".% Tool Runout Detecting System ACCRETECH View from arrow A GND SENS NC OV 24V FG I/ORS-232C (11.3) П7.5 П6.5 6.5 10 20 5 51001030 (П3.2) Cable length: 3.5mProtection cap M6x0.5 Marked tube (ID 3) (Serial No.) 5P"NQMJGJFS6OJU E-DT-ED02A-234 (with protection cap) (45.3) 2.5 27.313 П13 100 5 П21 (П3.5) 517 (19.6) Cable length: 3.5m Protection cap M12x1.0 Marked tube (ID 3) (Serial No.) To Amplifier Unit E-DT-ED03A-233 (with protection cap) ˙ Sensor Head Installation Precautions Note 1) Do not cut or add extensions to sensor cables. Be sure to check the sensor draw length before use. Do not touch maked tube ares, but cut within twisted portion. Note 2) The Sensor Head has passed waterproof structure (standard IP67) and coolant resistance properties tests. This does not, however, mean that resistance to all coolants is guaranteed. Note 3) A replaceable “protection cap” is attached on the Sensor Head as a measure against wear caused by chips. Do not remove this protection cap during use. Note 4) Pass the sensor cable through the protective duct to protect it from chips. Ensure a cable bending radius of 35 mm or more. Note 5) The overcurrent sensor controller and overcurrent sensor head set are adjusted before shipment from the factory. Be sure the serial numbers of the amplifier unit and sensor head match before connecting them.
Laser Interferometers/Built-In Type Measuring Instruments ˙ I/O Specifications I/O signals (PLC interface) No. ID Input No. ID Output 1P ink 1 Judgment start 14 Yellow 4 Run-out OK 2P ink 2 Tool registration 15 Yellow 5 Run-out NG 3P i nk 3 Rotation speed notification 16 Yellow 6 No tool 4P ink 4 Data No. 1 17 Yellow 7 Judgment complete 5P ink 5 Data No. 2 18 Yellow 8 Ready for measurement 6P ink 6 Data No. 4 19 Yellow 9 Sensor error 7P ink 7 Data No. 8 20 Yellow 10 Data mismatch 8P ink 8 Data No. 16 21 Green 1 Data FULL 9P ink 9 Data No. 32 22 Green 2 N.C. 10 Pink 10 Data No. 64 23 Green 3 N.C. 11 Yellow 1 Data No. 128 24 Green 4 N.C. 12 Yellow 2 Data No. 256 25 Green 5 Output COM
13 Yellow 3 Input COM
˔ Make sure to ground the shielded wiring. ˔ Do not connect any terminals to the empty items. ˔ Input signals: [Refer to the I/O Signal Interface Example.] (10 mA or less per signal) ˔ Output signal: Use at DC 24 V, 40 mA or less. ˔ Connector (25P, made by JAE) ˔ Cable OD П10.8 interface cable ˔ ID Example: [Pink 7] Insulator color: Pink ˙ I/O Signal Interface Example ˙ Open drain output (current sink connection) ˙ Open drain output (current source connection) ˙ Photocoupler input (current sink connection) ˙ Photocoupler input (current source connection) Controller side 40mA or less 24V Output signal Output signal CR PS7113L-2A(NEC) or equivalent PS7113L-2A(NEC) or equivalent Photocoupler 3.3KΩ CR 40mA or less 24V Output signal Output signal Photocoupler Controller side PS7113L-2A(NEC) or equivalent PS7113L-2A(NEC) or equivalent 3.3K Ω Controller side C ʴ PS2805-4(NEC) or equivalent PS2805-4(NEC) or equivalent No-voltage contact such as a relay 3.3k 3.3k E C E Input signals COM 24V Photocoupler Controller side C ʴ PS2805-4(NEC) or equivalent PS2805-4(NEC) or equivalent No-voltage contact such as a relay 3.3k 3.3k E C E COM 0V 24V