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In modern machining centers, inductive sensors are the elements of choice for monitoring motor spindle clamping processes. Being integrated into the spindle, they must be small in size and have high repeatability accuracy to ensure easy tool change at any time. For the implementation of more efficient intelligent spindle solutions, Baumer offers a range of powerful miniature detectors. This offers the classic version, with three switching detectors, or the intelligent version with one measuring detector.
In automated machining centers, it takes less than a second between removing a tool and replacing it with another tool in the spindle. These centers must operate as reliably as possible to ensure maximum machine performance. The perfect functioning of the smallest inductive sensors plays a decisive role here. In order for the machining center to operate smoothly, the machine control requires the following information about the chuck status: open and no tool gripped, closed and no tool gripped, or closed and tool gripped. Inductive sensors provide this information using three switching inductive sensors or one measuring sensor.
XXL range, miniature detectors
In drive and clamp solutions, sensing technology is integrated into the motor spindle. In these tight spaces, the detectors must be as small as possible while remaining efficient: this is where Baumer detectors come in. The Swiss detector manufacturer is said to have the widest range of miniature and sub-miniature inductive detectors with micrometric precision on the market.
The IFRM 03 proximity switch, with its diameter of only 3 mm, is part of this range. It is available in several lengths, the shorter variant measuring just 12mm. The miniature housing contains the entire electronic evaluation system allowing the management of reproducible switching points as well as the precise measurement of analog values. These industrial detectors are also compact, EMC shielded and correspond to protection class IP 67. Heat, oily environments and vibrations, common phenomena in machine tools, have no influence on the detector. Baumer has decades of experience in the manufacture of miniature detectors.
Measurement replaces switching
An analogue inductive distance sensor replaces the switching sensors which detect the three positions of the tie rod. This requires the presence of a cone on the tie rod instead of a plate. The measuring detector can recognize the position of the tie rod and therefore the state of the chuck using a cone connected to the tie rod. The distances or voltage values evaluated in the order can be assigned to the three positions of the tie rod.
The use of a measuring detector offers several advantages: Firstly, one detector takes up less space than three individual switching detectors and therefore requires less assembly work. In addition, the detector monitors the condition of the clamping system continuously. It also makes it possible to detect a loosened or poorly centered tool during tightening, especially in the event of the presence of chips between the spindle and the tool. Their presence can damage the tool or alter the quality of the workpiece.
The reproducible precision of tool clamping is optimized by means of Baumer sensors. They reduce the risk of a potential runout of the tool in place and detect it as early as possible. A measuring detector improves the reliability of the clamping system and guarantees the quality of the machining as well as the availability of the installations, allowing an increase in the overall rate of return. Micrometer accuracy of the detector, the largest possible detection area and less temperature drift are prerequisites. In this regard, Baumer's AlphaProx small inductive distance sensors offer, according to the manufacturer, “the best performance on the market. "
The reliability of the measured values as well as their high precision give the user maximum reproducibility when clamping a tool. Baumer offers one of the smallest inductive distance sensors on the market: the analogue inductive sensor IF08. This product range offers a 16 x 8 x 4.7 mm parallelepiped housing. This box contains the entire electronic evaluation system as well as a hole for flexible mounting, even in tight spaces. The measuring distance is 2 mm with an output signal of 0-10 VDC.
Flexibility guaranteed by IO-Link
The IR06 series miniature inductive distance sensor with IO-Link interface offers even more flexibility thanks to its housing which is only 6.5 mm thick and 46 mm long. The standardized interface makes it easy to integrate the tightening process into the order. Measured values can be recorded and analyzed on a chart to quickly detect measurement deviations and facilitate potential error analysis. It becomes possible to detect the smallest changes due to vibrations during the process to remedy them before a part is damaged. In addition, the detector provides additional diagnostic data, including detector temperature, useful for machine tool builders to indirectly detect spindle heating. The detector also offers all the advantages of IO-Link, such as easy parameterization and quick commissioning of a replacement detector by downloading parameters from IO-Link Master using the parameter server function.
The complete line of miniature inductive sensors provides the user with significant flexibility to set up a reliable tool clamping process solution. It is up to the customer to choose between monitoring his tightening process via switching sensors or a measuring sensor.
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