PCS-ER+ Broken Tool Detector (Complete System Kit) - Drill Tap Detector

Fast detection of broken drills in your machining cycle. Must have in lights out operations, screw machines and applications where its costly to scrap out parts or where quality control is a must. This broken tool sensor type is sometimes known as a whisker wand tool detection switch. Detect broken tools on CNC machines, drill machines and other applications with an highly efficient solution. Tool broke detection in CNC machining applications are often in an environment that can be hard on any equipment, but these tool breakage kits are well sealed and hold up to the challenge. Many people believe tool checking greatly reduces cycle time and when looking at the facts and proper installation, cycle time is minimal and in some applications non-existent since it can also be setup out of the work envelope.

Great for manufacturing environment and holds up to the coolants:

• CNC Machinery - Lathes & Mills
• Screw machines & Transfer Lines

Applications:

• Detect Broken Drills, Taps, Reamers, Chipped Inserts or any other tool.
• Detect chip build up on tools
• Detect wrong tool called up in program
• Detect a part loaded in chuck properly
• Detect part ejected from chuck properly

Watch this video on operation of this unit

Top Benefits to Save You Money:

• Reduce Scrap Costs: Eliminate quality issues and scrap parts, saving you thousands of dollars.
• Avoid Crashing Your Machine
• Minimize Downtime: Ensure continuous operation with reliable tool breakage monitoring.
• Lower Repair Costs: Prevent damage to your equipment with early detection of broken tools.

Download the Instruction manual for interfacing, operation, troubleshooting.

The PCS-ER+ sensor is equipped with an AC Brushless Motor also known in the industry as a Permanent Magnet Synchronous Motor or (PMSM), fitted with its own Integrated Drive System.

Far superior to its forerunner, the PCS-ER+ automatically learns its home position at start up and it is immediately ready to learn the position to be monitored.

The PCS-ER+  learns and remembers tool or object location at the touch of a button through 355 degree of CW or CCW swing direction.  This unit can learn ONE position out of the box, and can use CANOpen to test MULTIPLE TOOLS.
 

It has a bandwidth that varies ±2 or ±6 (switchable) Degrees around the taught location(s). The other commonly seen version the PCS-350 Broken tool detection system for applications that that allow for more space, and need just 1 or 2 different tool checks

The PCS-ER+ System combines the unsurpassed performance of an AC Brushless Motor technology, the tough, compact construction of innovative rotary position tool-sensing equipment, and powerful software that is simply logical, straightforward and operator-friendly that's unlike anything to come along in swing type sensors in years.
The PCS-ER+ is CANopen® able. Based on the Control option selected, the system can communicate and be integrated, with the use of standard cabling, into a CANopen® grid, allowing for simplified installation and networking of multiple sensors.

Legacy Mode Feature - This allows users to take advantage of a simple mode of operation (as it is for the PCS-100) where it is not necessary to teach a position but instead you just monitor presence or absence within a specific swing angle (much like it is for the PCS-100), however, this angle can be easily changed electronically. Also, the swing angle of the Sensor it is not limited to 170° or so (as it is on the PCS-100) but instead you can go about 350° on either the PCS-350 or the PCS-ER+

Variable Tolerance Feature - The PCS-350 and the PCS-ER+ NOW also offer Variable Tolerance of the detecting angle from ±1° to ±20°. This is particularly useful when trying to monitor different tool diameters within the same setting and want to avoid getting false positive feedback from the sensor.

Teachings and Diagnostics

After mounting, teaching the sensor a tool or object's location is as simple as pressing the teach button on the control box. Once the entire swing cycle has been learned, any low tolerance deviation from those parameters will be interpreted as a fault condition. This signal is instantly passed to the machine's cycle stop or feed hold control.

A system fault will also occur if electronic failures exist between the sensor and the control box such as in the case of a cable disconnect or short.

This unit comes with a 2 Year Warranty from the Date of Purchase

Broken Tool Detection Kit Applications:

• CNC lathes
• Vertical and horizontal machining centers
• Drill machine tool break detection
• Part removal/seated confirmation

How does detecting broke tools save you money?

• Less scrap parts
• Eliminate machine downtime due to a crash
• Reduce sorting time figuring out how many parts you ran without that tool
• Quality control issues
• Reduce manual part rework costs
• Free space monitor - Make sure area all clear

What does this Tool Break Detection Kit come with?

1. PCS-ER+ Tool break detection unit - Positive contact sensor (PCS-ER+)
2. BSC-3000 Control Box (operates on 24vdc - additional power supply may be needed) (BCS-3000)
3. 5 Meter oil resistant shielded cable M12 4wire (Longer lengths available upon request/additional charge 5m straight standard)
4. Mounting Bracket Clamp collar
5. Flat sensing needle 140mm (5.5 inch) - for small tools to prevent breaking   (Longer sensing needle available for additional cost 8 inch  10 inch)
6. Wrench Kit for adjustment of head (BSA-WRC_K)
7. Tech phone support for setup and installation.

Additional options that may be purchased separately

• Replacement Sensing Needle
  Extra Length sensing needles -  8 inch  10 inch
• Power supply- 24vdc power supply for 110vac/220vac applications
• Magnetic sensor base
• Coolant Guard Swing Arm Assembly
• BSC-MOP-4 Manual Control for PCS-350
• BSC-CAA / BSC-SPD Combo for PC to Device communication

PCS-ER+ Tool Broken Detect Features

• Teaching of UNLIMITED POSITIONS using CANOpen Interface Library
• Settable Home Position
• Object Presence Monitoring
• Anodized Aluminum Body just 18 mm in Diameter
• 0-355 degree electronically learned swing range. Complete diagnostic system
• Permanent Magnet Synchronous Motor or (PMSM), fitted with its own Integrated Drive System
• CW and CCW swing
• Checking window tolerance of ±2 or ±6 Degrees (Switchable)
• IP67 rating - Completely sealed against liquid and solid contaminants. 
• Maxi Life needle in standard or special length
  Standard: 140 mm (5.5 in.)
• 90 degree or straight, molded 5 pin connector/cable
  Cable lengths to 75m (246ft)
  Standard length is 5m (16ft)
• Micro tool and micro drill sensor capability

Mounting locations/Ideas
Use 80/20 or similar extrusion and bracket to make mounting easier within the machine. Otherwise weld up some metal brackets to mount sensor.

CNC Vertical – Table mount - 1) Drape wire from back corner wall OR run wire into table openings if available OR utilize existing wire track to run new. May be possible to utilize spare wires in junction box if the exist for machine options not used in which case you can disconnect from machine on both sides to use.

CNC Horizontals – Rotary B axis - Cable routing into cast, through existing wire track (see if spare wires available and not used otherwise route another cable through tracking.

Tool magazine mount - Limited to fixed location amd no Z depth movement if setup this way.

Lathe - Check Turret Tools or part evacuation from subspindle or chuck type applications

• Chuck Wall mount
• Mounted to Tailstock/lower machine area somewhere with Z axis retracted
• Turret body mount
• Subspindle mount

This unit comes with a 2 Year Warranty from the Date of Purchase

If you would like to discuss your application - Call us (414) 881-4493

• Download the Instruction manual for interfacing, operation, troubleshooting.
   
• Example PCS-Tool Breakage application photos, setup and installation - Click here

Tool broken detection systems for CNC applications are a must in manufacturing. Tool sensing and tool monitoring system.

This unit is made in the USA