Tool monitoring in real-time

Paul Horn is now changing that with the Piezo Tool System, developed in close cooperation with the Kistler Group. Thanks to this tool monitoring solution, any breakage can be recognized at an early stage, minimizing production downtime. Moreover, it is compatible with standard tool holders and conversion requires no further modifications to the machine. 

In close cooperation with the Kistler Group, Paul Horn GmbH has developed a globally unique solution for real-time tool monitoring of turning operations. Kistler is the global market leader for dynamic measurement technology for recording pressure, force, torque and acceleration. 

Measuring even smallest machining forces

The Piezo Tool System (PTS) consists of a force sensor, which is placed in the turning tool and provides information about the state of the tool during machining. With the system, forces as small as a few Newtons can be measured. The standard scanning frequency is 10,000 Hz. Thus, even very small machining forces can be measured. The machine operator can thus immediately identify incorrect materials and cutting materials or also a tool breakage. This leads to minimal waste and high quality. In addition, the operator can specifically assess the tool life of the tools used. Horn offers the sensor-monitored toolholder as a turning holder for square shafts, as a linear unit for Citizen long-turning machines and as a basic holder for INDEX machines with multiple spindles as well as for the Supermini tool system. Other interfaces for other machine manufacturers are currently being developed.

Ideally suited for turning operations

The PTS system is ideally suited for turning operations. For this, alternative measurement methods such as monitoring the drive power of the main spindle motor do not make sense because of the small deviations. Even a measurement of contact noise does not provide consistently satisfactory results for small workpieces. And even visual monitoring is not possible because of the cooling lubricants and high rotational speeds in the machining process. The PTS solution is compatible with selected standard rotary holders from HORN. No modification of the CNC control is necessary. The system can be used machine-independently and takes up very little space in the machine. The PTS system reduces production costs and increases production capacities.

Trouble-free conversion

Conversion from standard holders to the PTS holders is trouble-free and required no other changes to the machine. Despite the installed measuring technology, the tool holders are very stable. In terms of application, the PTS linear unit does not differ from the standard linear unit. All standard tools can be mounted. Tool change and adjustment are also identical to those of a standard linear unit. The standard base holder 968 for INDEX machines with multiple spindles can also be replaced 1:1 by the PTS base holder 968. The holder system is suitable for all HORN tensioning cassettes type 842. Tool change, cassette change and peak height adjustment are identical to the standard tool.