Tool Condition Monitoring System Using Acoustic Emission

Timely detect potential problems, improve production efficiency, ensure product quality and reduce production costs

Why Acoustic Emission Technology?
During machining, problems such as tool wear, workpiece collision, and grinding wheel abnormalities (such as wear and breakage) directly affect machining quality and equipment life. Traditional monitoring methods rely on manual inspections or equipment feedback, which have problems such as slow response, low accuracy, and unpredictability.
As an effective monitoring method, acoustic emission technology can capture high-frequency sound wave signals in the process of tool and workpiece processing in real time and realize millisecond-level abnormality identification. The acoustic emission monitoring system can timely detect potential problems, improve production efficiency, ensure product quality and reduce production costs by monitoring various state parameters in the processing process in real time.

Principle
During machining (cutting, grinding, punching, milling, etc.), the contact surface between the tool and the workpiece generates sound waves which are received by sensors installed on the workpiece or the tool. Different machining conditions (normal, tool wear and damage, excessive feed, workpiece finish, etc.) have different sound wave emissions. The collector analyzes the sound waves and gives the status results. The machine tool system takes measures (changing tools, stopping, reducing feed, etc.) to avoid quality accidents and extend the tool life.

Technology Advantages
- Flexible and quick installation
- Wireless data transmission
- Auto classification and alarm
- Available for secondary development
- AI Tools available

> Ultra-fast response: output shutdown signal within 1ms, quickly achieve normal contact and grinding between the grinding head and the workpiece, improve efficiency, and prevent collision damage

> Strong anti-interference: digital filtering and hardware filtering are combined to eliminate environmental noise interference

> High stability: IP65 protection, stable operation in -20~60℃ environment

> Quick deployment: non-invasive installation, the equipment adopts magnetic suction to achieve non-invasive rapid deployment.