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