Drill Bit Breakage Detection Sensor [DFM Series]

Drill Bit Breakage Detection Sensor DFM Series

Air-driven needle for detection of tool breakage

Mounted on machine tools such as automatic machines and special-purpose machines to detect breakage of drills, taps, and reamers. It prevents defective workpieces caused by tool breakage.
One of the main feature is that this sensor is highly coolant-resistant unlike motor-controlled sensors.

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Features

IP67 protective structure, outstanding durability against coolant

The world’s first air-driven system!
Without the use of a control motor, this sensor demonstrates outstanding durability even in adverse environments inside the machine tool where it is exposed to chips and coolant.
Users will achieve significant reduction in maintenance costs caused by breakdowns.

Achieves affordable tool breakage/damage detection.

Eliminates the need for expensive control motors and control units.
The mounting diameter is M22, and it is also interchangeable with conventional parts.

High reliability + Low cost: Fewer false detection achieved by touch sensor method

Since the detection is made by the needle’s direct contact with the tool, coolant splatter or mist is less likely to interfere when comparing with expensive non-contact sensors (e.g., laser sensors), thus ensuring high reliability.

Main Specifications

Product name	DFM3
Purpose of use	detection of tool breakage/damage detection.
Contact Shape	φ1.5 needle
Protective structure	IP67
Contact Force	0.1N
Cable	Length３m　Oil resistant φ4 / 5 cores　Minimum bending R7
Accessories	Sensor mounting nuts (×2), Air hose clamp (×1) , Needle adjustment pushing rod (×1)
(Over travel signal) Output mode	Please check the product Catalog and Manual.
(Over travel signal) Contact rating	Please check the product Catalog and Manual.
Operating temperature range	0 - 60℃　(Ice-free)
Working air pressure	0.4 - 0.5MPa（dry air） Air tube diameter: φ4 × 2.5
Output specification	Open collector （type: C-DF-01N output: NPN）（type: C-DF-01P　output: PNP）
Power supply voltage	DC+24V
Drive method	Pneumatic drive type (single-action push-out air cylinder type)
Signals	3 signals
Direction of needle rotation	Clockwise / counterclockwise
Stroke (rotation angle)	100°
Minimum tool diameter	φ0.5mm (For small diameter drill bits φ1mm or less, refer to catalog p12-3)
Needle Specifications	Length: 100mm（from center of rotation） Thickness: φ1.5 Material: Quenched SUS420 HRC50
Net weight	Approx. 250g
Type	C-DF-01N / C-DF-01P
Current consumption	10mA
LED display	Origin: Green, Judgment: Red, Stroke end: Yellow
Output rating	DC24V　150mA (MAX)
Insulation resistance	100MΩ with DC250V megger
Withstand voltage	AC500V, 50/60HZ for 1 minute between each pin and case
Protective circuits	Reversed power connection protection, Surge protection

Names of Components and Internal Structure

How it Operates:

The driver turns the home signal ON at the home position (LED lit green) and the end signal ON at the stroke end position after operation (LED lit yellow). If the cutting tool is damaged (or not present), the needle rotates to the stroke end position, the evaluation signal is turned off, and the LED red turns off.

If the cutting tool is in good condition, the needle stops after contacting the tool and does not reach the stroke end, so the evaluation signal remains ON and the LED remains lit.

To determine whether or not the cutting tool is broken, please transmit the evaluation signal ON/OFF (LED red light ON or OFF) at the point when the stroke end signal is ON (LED yellow light ON) to an external device.
*The stroke end signal is turned ON at every stroke regardless of the condition of the cutting tool (good or damaged).