Tools Can Break at Any Time. Be Prepared.
Positive Contact Sensors (PCS Sensors) can detect broken drills, taps, end mills, or reamers before the cost of chain reaction broken tools, machine damage, downtime, and scrap breaks you.
How Does it Work?
Regardless of which PCS Sensor System you choose, the system will consist of two main components – a Sensor and a Sensor Control Unit. The Control Unit is typically mounted in the machine control cabinet and the sensor is bracket mounted close to the cutting tool. Tool monitoring is performed by a light physical contact of the tool tip with the needle of the sensor. The sensing needle is typically used straight but can be bent in many configurations depending on your application. If the tool is present, the needle will contact the tip and return to the starting position. The cycle will then be allowed to continue. If the tool is broken, the needle will swing past the tool and interpret the condition as a broken tool. The unit will then send the appropriate output to the machine control to either stop a cycle or call up a redundant one. The system can also be used in reverse logic. In that case, you would allow free unobstructed space to be an acceptable condition, while an obstruction would generate a fault.
Brushless Tool Check Technology
Allora has dedicated substantial resources in the development of new technology tied to the PCS product line. As a result, Allora is now offering the most innovative tool monitoring device of its kind. Other products available on the market, including the older generation PCS-100 and PCS-250, use a brush style motor. Some other manufacturers also incorporate miniature gearboxes, known to fail over a limited amount of time.
The innovative design of the PCS-350 and the PCS-ER+ no longer relies upon a weak brush motor design (often affected by developing commutator dead spots); instead, it is built around strong and reliable Brushless Motors–known in the industry as a Permanent Magnet Synchronous Motors or “PMSMs”. Join in and discover the benefits of PCS Brushless Technology!
The PCS-ER+ and PCS-350 both can operate with Allora’s Controller. It is worth noting the PCS-ER+ specifically, can operate without an external controller, as it already has a very powerful miniaturized integrated controller right inside the sensor. This handy feature allows an OEM user to operate the PCS-ER+ sensor directly from a proprietary control utilizing standard CANopen® Protocol. To aid in this effort, Allora developed Adaptive Touch Technology®: an extensive Function Library Code and Software incorporated inside each of the Sensors supplied from Allora. Read all about how to incorporate this exciting new technology in the Allora OEM User Manual.
Which System Do I Need?
Now you can select the Positive Contact Sensor that best suits your needs and budget. The PCS-350 and PCS-ER+ are free of miniature gear boxes and share other common features that make them ideal for automatic machines operating in the toughest environments and under lights-out conditions. The technical differences between the various sensors can be found in three general areas. The first is the method of setting the sensor for operation, the second is how their diagnostic systems operates and the third is tied to the actual operating technology of the sensor differentiating a standard DC brush motor from an Advanced “AC Servo” Brushless Motor Technology.
What’s New
NEW FEATURE: The PCS-350 and PCS-ER+ have the ability to set multiple tolerance angles with an adjustable window from ±1° to ±20°.
NEW LEGACY MODE for the PCS-350 & PCS-ER+: Allows the system to operate just like the older PCS-100 Sensor with fixed yet settable angle (now easily adjustable electronically).
INTRODUCING THE BSC-MOP-6! Allows user to set up the monitor right in the machining area and test all various settings for control force & swing and the adjustable swing angle.
The Danger of One Undetected Broken Tool
CNC lathes are frequently changed over for different part set ups. It is not uncommon to find one or more tools in each set up which are problematic and prone to breakage. Left undetected, the typical result will be an expensive chain reaction of broken tooling, scrap parts, down time, sort time, and more. Positive Contact Sensors provide a simple and affordable solution to protect your company’s profits.
One of Our Customers Said it Best
“It’s there when I need it and idle when I don’t…It’s cheap insurance”
