Our TOOL MONITORING PACKAGE has been developed over the last five years as a cost effective alternative to other tool protection systems which have limited functionality and effect. The system is designed to detect worn, damaged and missing tools in high volume production machinery. Timely detection of these conditions provides the following benefits.
• Minimisation of scrap and rework.
• Realistic tool life based on individual tool wear rather than fixed life counters.
• Maximum utilisation of expensive tooling.
• Protection of other elements of the machine power-train.
• Prevention of incomplete components arriving at later machining operations.

How does it work ?
Essentially each tool is constantly monitored against a pre-stored "model" profile during the cutting cycle. The load profile can be either torque from feed slides or spindles of the machine, noise from a microphone or vibrations from accelerometers. This ‘model’ profile is taught over several teaching cycles and will be compared to the actual transducer value during the machining operation. If excessive torque (or noise or vibration) is detected then the CNC will be informed and the slides can be stopped or returned. In addition wear limits can be entered to inform the operator when the tool wear occurs. In the following image, the green line shows the taught average cutting torque, the yellow line displays the actual cutting force during the machining cycle.

Each tool monitor system can monitor up-to 16 analogue channels and process up-to 16 cutting operations simultaneously with a starting price of under £3,000.00.


The source of the ‘load’ profile can be configured from a wide range of transducer sources and types of signal input. The system is extremely flexible, allowing individual tool monitors to be configured using various parameters and settings.


The system can be installed on virtually any existing PC based CNC platform or can be supplied on a stand-alone PC. In its basic format the system provides up to 16 independent analogue monitor channels (expandable) plus digital I/O signals to interface to your CNC, PLC or motion controller.

Depending on the nature and stability of your process, tool monitor can be configured to work in different modes to provide optimum protection of your tooling whilst eliminating ‘nuisance’ tripping. In addition, tool wear trends and historical data can be recorded for later analysis.



For further details and pricing options phone
+44 (0)2476 545711
or email sales@ccstech.co.uk

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