Detect Broken Tools Without Chip, Coolant Misreadings

The TRS2 broken tool detection system combines laser source and detection electronics in a single unit measuring 3.27" × 1.50" × 2.87" (83 × 38 × 73 mm). Unlike two-part systems, the device’s single-box construction allows mounting flexibility to optimize working space and processing routines, the company says. The system can detect a range of solid-center tools, including drills, taps, reamers, slot drills, standard and ballnose end mills and gun drills. It can process tools as small as 0.2 mm.   The laser system offers a wide detection range of 13" to 80" (0.3 to 2 m). The company says its custom Toolwise electronics technology prevents misreadings caused by coolant and chips. This system works by analyzing reflected light patterns from the rotating tool as it enters the beam, distinguishing between the random patterns generated by coolant or chips and the regular patterns generated by the spinning tool. A repeating pattern represents a good tool, while a non-repeating pattern indicates a broken tool. The electronics can detect and process reflections off both bright and dark tools.   To cover a range of applications and tooling, the system works at three different speeds. The default speed, 5,000 rpm, provides the shortest cycle time, while 1,000 rpm is suited for large, heavy tools. The slowest speed, 200 rpm, is intended for gundrills. According to the company, the tool-recognition process takes about 1 second.