Product category:
Monitoring and sensor equipment and systems
News Release from: Haimer, Franz | Subject: Universal 3D-sensor for milling and EDM
Edited by the Manufacturingtalk Editorial
Team on 26 September 2001
3D-sensor sets tools quickly and
precisely
The universal 3D-sensor made by Haimer is a very precise and versatile measuring instrument for use in milling and EDM machines.
The universal 3D-sensor made by Haimer is a very precise and versatile measuring instrument for use in milling and EDM machines It allows milling spindles and vertical tools to be positioned fast and accurately on edges of the workpiece or on fixtures, it also allows to set the machine coordinate-system and to measure lengths
This article was originally published on Manufacturingtalk on 26 Sep 2001 at 8.00am (UK)
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If a job needs to be machined using a milling or an EDM-machine, a reference edge needs to be determined in order to define the position of the job to the machine controlling system.
This is normally accomplished by using a mechanical approach sensor (edge finder).
This pin is approaching the appropriate edge with its tracing ball.
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Upon contact it will move or produce an electric contact signalling to the operator: position reached.
This process is, however, not very problem-free, because it can take some time until the contact point is precisely found.
If the operator is not paying attention very well, he will advance too much and he will have to return and start again.
If the ball has found the correct contact point, the spindle axis is still by one radius away from the edge.
This means the result of the measuring system needs to be corrected by the radius.
In doing so the direction of travel needs to be taken into consideration as the value will have to be added or subtracted.
Mistakes can easily occur in such a case.
In order to simplify this procedure, the Haimer, Igenhausen universal 3D-sensor had been developed.
The working principle of this sensor is similar.
The sensor is being clamped in the spindle using the tool-holder.
Only if the tracing ball contacts an edge, it is not the contact point that is of interest, but the dial gauge.
As soon as the ball is pushed out of its original position, the gauge will start indicating.
With a ball radius of two millimetres the gauge will start at -2 mm.
In the "O"-position, i.e the ball centre, the machine is exactly positioned on the edge of the spindle axis.
In this position the measuring system is set to zero.
As you will also see during approach on the analogous handle how far an advance is still required, several trials are unlikely.
Another millimetre, again half a millimetre, still a few tenths of a mm - the operator will obtain the zero-position straight away.
Even the indicated measuring tolerance of 0.01mm can still be improved thanks to the analogue gauge which is able to recognise an incorrect position on the reading by 2 microns.
The 3D-sensor works in any direction, so the operator can turn the spindle in a way that the gauge can be seen easily.
The 3D-sensor can also be used in the z-axis for instance for measuring purposes.
The operator will set the measuring system to zero on the tables surface using the Haimer 3D-sensor and he will trace the job surface with the sensor.
As soon as the dial gauge is in this position in the zero position, he can read the workpiece's height on the machine control.
In order to obtain optimum precision it is advisable to set concentricity before starting the work, as the spindle and the tool-holder indicate always a certain deviation.
If the spindle rotates, this will result in a concentricity error on the measuring ball and consequently the measuring result will vary depending upon the position of the rotation.
Therefore during the first use of the sensor concentricity should be set as precisely as possible.
As the measuring sensor is usually staying with its tool-holder at the machine - the 3D sensor is only costing 360 DM (about GBP120 in Germany), so that one can afford one per every machine - this is a unique activity lasting about 10 minutes and it will pay off as to measuring accuracy.
The Haimer 3D-sensor is spray-water-protected so it can also be stored in the tool-change compartment.
It is true that it is used frequently and not only for setting jobs.
It can also perfectly be used for centring holes and shafts.
The Haimer universal 3D-sensor is available in various versions.
The "normal" version has a 20 mm shaft, which can be clamped in a tool-holder.
Upon request small shafts are also available.
The smallest has a diameter of 8 mm.
In the "integrated" version tool-holder and sensor are integral.
This is slightly shorter and in total slightly cheaper.
In addition to the sensor with an analogue dial gauge Haimer has also a version with an analogue gauge.
It can be read from a larger distance and even more precisely.
In addition it can contact within a tolerance range of 5microns and therefore it is more precise than with the analogue sensor.
Another advantage is that the gauge can be switched without any problems to inches.
However, this sensor is much more expensive, it costs almost double as much.
Both versions can be provided with two different inserts, a short and a long one.
They are bolted together and can be replaced easily.
Both versions have a measuring ball a red element made of ceramics.
This element has two functions: for one it serves as an intended fracture line - if the operator is feeding too much and the mechanic system comes to an end.
In this case the gauge is not damaged and a new insert can simply be installed.
An other function is insulation of the measuring ball.
There is no electric contact between the ball and the casing which allows the sensor to be used for spark erosion machines as well, a machine type which will normally stop functioning upon an electric contact for safety reasons.
If the customer should really intend to crash the system, he can return the universal 3D-sensor to Haimer.
Haimer's repair service will repair, pre-set, re-calibrate and return the sensor.
HAIMER(r) made by haimer ? Franz Haimer GmbH, Weiherstraáe 21, D-86568 Igenhausen, 0 82 57 / 99 88 -0.
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