The second-generation TRS2 broken tool detection system from Renishaw is said to save space and install easily on smaller machine tools used in medical part machining. The system’s “one-box” design combines the laser source and detection electronics in a single, compact unit that measures 3.27" × 1.50" × 2.87" (83 mm × 38 mm × 73 mm), enabling mounting outside the work zone. The system can detect a whole range of solid center tools, including drills, taps, reamers, slot drills, standard and ballnose end mills and gun drills. The system can process tools with diameters as small as 0.2 mm in 1 second, and it offers a detection range from 0.3 m to 2.0 m.
The company’s Toolwise electronics technology detects broken tools without misreading caused by coolant or chips. The technology analyzes reflected light patterns from the rotating tool as it enters the beam, rejecting random light patterns created by coolant or chips. Tool edges generate a regular light pattern as the tool spins, while chips and coolant give random reflections. A repeating pattern represents a complete tool, and a non-repeating pattern indicates a broken tool. Both bright and dark tools reflections can be processed.
Monitoring can be provided at three different tool rotation speeds—5,000 rpm, 1,000 rpm and 200 rpm—to cover a wide range of applications and tooling. Used for high speed tools, 5,000 rpm is the default speed that gives the shortest cycle time. Intermediate 1,000 rpm can be used for large, heavier tools. The slowest speed, 200 rpm, is intended for gun drills.