:: Static AE-Sensors
These sensors can be used for stationary dressing tools, single point diamond and blade type diamond. They could be mounted on the dresser, on the workpiece headstock, the tailstock or spindle housing. Not only for monitoring the dressing process but also possible to control the complete grinding process. The sensors are characterized by their easy installation, as well as their high signal quality. The static sensors are available in different shapes, sizes and mounting options. (read more)
AE fluid sensor:
The AE-Signal will be transmitted in the opposite direction of to the flow of liquid jet from the machine's coolant system (coolant or cutting oil emulsion). By electrically and acoustically isolating the AE fluid sensor from the machine tool, We have managed to suppress the machine’s background noise.
:: Rotating AE sensors
The contactless AE sensors M- and Mini-M sensors are provided, for example for mounting on form rolls or profile rollers and can be mounted directly in the center of the grinding wheel or a dressing wheel. The simple assembling and measurements on the rotating shaft provide optimal signal to-noise ratio, speaks for itself.
For installation in dressing or grinding spindles, the Micro M-sensor would be the right solution. The sensor could be monitoring both, the dressing and the grinding process, we pick up the signal directly where they occur.
The customized adapted AE-Ring sensors can be installed on the chucks, on the grinding wheel spindle or on the dressing spindles. With the high-speed ring sensor - used for internal grinding and dressing systems, could pick up signals on higher RPMs.
Acoustic Emission Electronics
For the automation of grinding- or dressing sequences it is more and more important to optimize the process and safe workpiece quality. The acoustic emission (AE) signal is an ideal and safe quality of criterion for evaluation.
The AE-Signal of the S6000 will be visualizes over optical LED´s over the WINDOWS based machine. The Sensitron6 is a new type of AE evaluation electronics that can help to monitor and stabilize complex grinding processes. The high performance grinding process monitoring and control electronics are easy to integrate into the machine controls where they evaluate the signals detected by the highly sensitive AE sensors.
• Sensitron 6
The Sensitron6 reliably detects the initial contact between the grinding tool and workpiece, detects spark-up and automatically changes the feed rates in order to reduce air grinding time without loss of quality. An integrated crash monitoring function within the working space is a useful security measure that can minimize the costs arising due to collisions. One can select the sensors and operate the evaluation electronics either manually via push buttons or fully automatically via the machine controls. The AE signal is displayed on a LED bar graph (with 30 graduations). For the automation of grinding- or dressing sequences it is more and more important to optimize the process and safe workpiece quality. The acoustic emission (AE) signal is an ideal and safe quality of criterion for evaluation. The AE-Signal of the S6000 will be visualizes over optical LED´s over the WINDOWS based machine.
The P3SE is a monitoring system for grinding machines based on the technology of sensors with acoustic emission. The system is able to meet and solve the different needs by including the continuous check of process, check of end of gap elimination, wheel dressing and prevention of crashes. The P3SE is available as slide solution or with housing. For evaluation is has two physical-channels and four logic-channels.
The 4100 series is ideal for visualising and monitoring grinding processes on grinding machines where the machine controls are not equipped with their own monitor. The use of acoustic emission systems enables the user to optimize the grinding and dressing process, to reduce air grinding and to monitor for collisions between grinding wheel and workpiece. The entire 4100 series is menu-controlled (in 5 languages) via the displays on an illuminated, monochrome LCD monitor. The electronics evaluate the data provided by highly sensitive acoustic emission sensors. One can save up to 31 envelopes and their related parameters.
The use of this system helps to optimize grinding and dressing processes and reduce the amount of air grinding. The device is controlled via the menu displayed on an illuminated, monochrome LCD monitor. Dynamic thresholds can be evaluated using the additional envelope monitoring module.
An additional envelope module inside the AE4100-1E monitors the process dynamically by taking measurements and evaluating the sensor’s output voltage over time. Any value that lies above or below the pre-defined envelope sends an error message to the machine controls.
The combined device AE4100-1P combines the functions of pre-balancing / Field balancing and process monitoring with each other. On AE4100-1P, a vibration sensor for monitoring the imbalance and up to four AE sensors can be connected.
Automated grinding or dressing processes must run safely and stably, and produce a consistent level of workpiece quality. Process monitoring on the basis of highly sensitive acoustic emission sensors combined with the AE6000 evalution unit is the ideal solution to improving process stability. This system can be used to reduce air grinding time, to detect first contact, to detect the first cut during touch dressing, dressing monitoring, grinding process monitoring and wheel damage or collision monitoring.
The DM6000 process monitoring module enables you to evaluate sensor-based and internal control data. The increased demands placed on the grinding process over the past few years have led to the introduction of new technologies. In order to make full use of a machine’s reserves at increasingly high cutting speeds, one must use the appropriate sensors to detect threshold values during the grinding and dressing processes. Should the measured data exceed the tolerances, corrective action can be taken before the process degenerates without intervention on the part of the machine operator. Internal control data, e.g. torque, is transferred via Profibus to the module where monitoring takes place. The data set for each monitoring strategy can be flexibly allocated to a signal source. AE/Crash, the voltage input and Profibus inputs are treated equally and can be used for envelope monitoring. When using digital drives, even sensorless process monitoring is possible with the aid of internal control data. Feedback to the controls is made via Profibus or static interface.