Tool breakage has always been a challenge for machining operations. These breaks can occur during regular machining cycles due to tool wear that eventually results in failure. They may also occur due to improper settings, human error, equipment malfunction, or for a variety of other reasons.
When tools break,costs pile up. Downtime meansfewer first-quality piecesand potential missed deliveries. It also drives up labor and materials costs from scrap and additional labor for reworkable pieces.
However, recent years have seen a growth in accurate and dependabletool monitoring systemsthat operate in conjunction with production monitoring to prolong the life of tools or predict their failure.
This article will define tool breakage, discuss common tool break detection technologies, and address ways to avoid a costly break.
CNC加工中使用了多种工具。工具破裂检测由控制系统技术组成，其中工具的断裂信号向破裂的操作员发出信号。
When these alarms happen, the machining cycle may stop, allowing operators to replace the tool and prevent damage to the machine. Depending on the type of break, tool detection can help recover a part before it becomes scrap.
工具休息检测提供了许多好处，包括：
There are several active technologies used in CNC machining that enable manufacturers to realize these benefits. The type of system used for tooling breakage detection may consist of one or more of the following technologies.
They’re often tied to production monitoring systems and ideally IIoT platforms that can analyze tooling data in the cloud to better predict breakages in the future. One innovation in the area of non-contact technologies is the use of high-frequency data that helps diagnose, predict and avoid failures. This technology is sensorless and uses instantaneous real-time data pulled at an extremely high rate to build accurate tool failure detection models.
Wired break detection systems are straightforward. The hardware used to detect breaks is physically attached to key components of the machine where breaks can occur. They’re usually less expensive than other technologies because the communication devices don't need to be embedded into hardware.
Wired systems are a good choice for tool break detection in equipment where the motion needed to work the piece is straightforward. However, the quality of analysis, alarm speed, and response speed when breaks occur will make the difference. Wired systems are only as good as the speed of the response, quality of the analysis, and insight yielded.
A benefit of wired technology is that it can be linked directly to a factory-wide tool monitoring solution. This vastly improves the quality of analysis of tool breakage allowing predictive and prescriptive strategies to bedeployed for better tool lifeand less breakage.
无线技术与有线技术一样准确。一个考虑因素是无线硬件到控制器的范围或监视生产并发送警报的平台的访问点。大多数商店都在范围不是问题的地方安排。
In wireless break detection, systems are usually Bluetooth or based on traditional RF. As wireless technology advances, the shift to Bluetooth-enabled devices, especially Low Energy Bluetooth, is beginning to replace RF. Wireless technologies can communicate directly with tool monitoring software solutions. Thisautomates the monitoring of tool wear和工具破裂，不仅在工具中断时，还可以确定它们接近故障点。
Contact detection technologies use a probe, pad, or other end piece to determine if a tool is broken. Probes can be fixed or moving, depending on the type of machine. Tools will contact probes to determine whether the tool is broken. Contact break detection can be used with both wired and wireless systems.
像有线技术一样，接触技术是检测工具破裂的物理方法。但是，这些接触设备可以加载到有线和无线系统中的工具监视软件中，以实时使工具中断检测。这意味着可以在立即检测后停止设备自动化以防止机器损坏并从废料箱中保存材料。
The most common non-contact break detection technology is a laser. Lasers are ideal for detecting breakage of high speed rotation of tools. They’re also highly useful in tools that require thermal monitoring that may deform or break the tool under excess heat. Lasers are only able to measure in two dimensions. For three dimensions, they’re paired with contact technology to capture third-dimension data.
另一个非接触式突破检测技术是使用相机。与激光器相比，摄像头对小工具更好。横梁通常比小工具中的工具宽，相机可以通过小工具铣削的高分辨率图片检测到断裂。
Tool breaks can be minimized through best practices and attention to detail. This helps minimize the cost of the tool and the overall production operation. Best practices include:
错误可能导致刀具破损。这里有服务les of common mistakes that lead to tool breakage.
When BC Machining sought help to address continuing tool breakage and high scrap rates, they engaged MachineMetrics for a solution. BC Machining serves the medical, defense, transportation, and power tool industries where precision is critical.
BC Machining had been experiencing excessive tool breakage in their Swiss CNC machines, creating scrap both at the point of breakage and near-end-of-tool-life when parts can vary out of spec.
BC使用捕获高频数据并通过高级算法进行分析的机械方法解决方案，卑诗省能够识别工具断裂以防止废料零件。
The drop in lost parts, sorting, and uncertainty translated into near 100% failure detection and a $72,000 annual savings per machine.
Read the complete case study with BC Machining.
机械学offers a monitoring system for tool assessment that collects data directly from the source – the CNC machine itself. Through custom algorithms designed to monitor torque usage, inputs can be entered into the system as time-series events or machine learning models to predict tool failure accurately.
Machinemetrics的高频数据适配器可以检测问题并分析边缘的数据以使解决方案自动化并提醒员工在发生故障发生之前的问题，从而防止昂贵的废料和停机时间。使用高级机器诊断，工具将被优化并纳入一种侵略性和全自动的预测维护系统中。要查看如何部署机械测量以帮助您满足工具的健康需求，book a demo with our team today.
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