PCS-350 Broken Tool Detection System (Complete System KIT) - Replaces Model PCS-100

For fast detection of broken drills in your machining cycle, a must have in lights out operations, screw machines and applications where it's 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 increases cycle time but 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.

This is a special application sensor. Please read through carefully before ordering. The PCS-350 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-350 automatically learns its home position at start up and it is immediately ready to learn the position to be monitored.

The PCS-350  learns and remembers tool or object location at the touch of a button through 355 degree of CW or CCW swing direction.  It can only learn up to two locations and has a bandwidth that varies ±2 or ±6 (switchable) Degrees around the taught location. Tighter tolerances on single spindle units, extended tolerance on CNC machines with multiple heads. The other version is most commonly see the PCS-ER+_S Broken tool detection system for applications that that need to fit in a tighter space  or need to check multiple types of tool heads. The PCS-350 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-350 utilizes the CANopen® bus. 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 confirmation applications

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 is in the Tool Breakage Detection Kit?

1. PCS-350 Tool break detection unit - Positive contact sensor (PCS-350)
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. Sensing needle 140mm (5.5in) 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

• Flat sensing needle 140mm (5.5 inch) - for small tools to prevent breaking
• 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-350 Tool Broken Detect Features

• Teaching of up to TWO Master positions
• Object Presence Monitoring
• Anodized Aluminum Body
• 0-355 degree electronically learned swing range. Complete diagnostic system
• Permanent Magnet Synchronous Motor or (PMSM), fitted with its own Integrated Drive System
• CW or CCW swing direction by selector switch
• Checking window tolerance of ±2 or ±6 Degrees (Switchable)
• IP 67 rating - Holds up in coolant environment
• 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
• Slim Profile of just 25mm
• Drills as small as 0.1mm

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