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Dull and broken tools monitor

Compensator dull tools and broken tools monitor

Senses precise motor power; Detects dull tools; Detects broken tools or missing tools; Detects misplaced work piece; Protects machine & process; Signal beginning or end of process; Overload protection; Prevent machine jam-ups; Sensitive self adjusting system; Optimise feed rates; Reliable high quality sensor
: Manufactured by Load Controls Inc

Self adjusting dull and broken tool monitor

The COMPENSATOR Motor Load Control (Model PCR1810), manufactured by Load Controls Inc, is a very effective unit for machine tool monitoring. This highly sensitive system allows sensing of the machine spindle power and set points are used to indicate dull tools and broken tools. By sensing power, rather than amps, it is sensitive enough to work with a wide range of tool sizes including small tools.

The control also has a compensating feature which will zero out the baseline power. The machine baseline power changes significantly as temperatures change, coolant and the lubricant viscosity change and the mechanical clearances change.

During each machine cycle when the process is in its baseline or idling position a contact closure is sent to the control from a limit switch (or from a programmable controller) and the control learns this value and retains it in memory during the next machine cycle.

The control then looks for an increase above this baseline value. By zeroing out the inherent machine drift , the control is quite precise. A special filtering scheme is used to insure fast response, it is easy to install since it requires no machine modifications and is a low cost solution.

For monitoring a single tool on a single spindle, the COMPENSATOR motor load controls detects dull tools and broken tools and performs just as well as the more sophisticated systems, which are much more expensive.