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Ultra-Fast Collision Monitoring and Crash Damage Mitigation in Machine Tools

The Brankamp CMS-02 system from Marposs monitors collision and mitigates crash damage in machine tools with a ceramic strain sensor used to detect irregularities in the production process.

Posted: April 19, 2018

The Brankamp CMS-02 system from Marposs monitors collision and mitigates crash damage in machine tools with a ceramic strain sensor used to detect irregularities in the production process. It measures elastic deformation and both slow and dynamically increasing forces with damage potential, then reacts within one millisecond by sending a stop signal to E-STOP to help alleviate or even eliminate machine crashes that can result in high repair costs and long downtimes.

The new Brankamp CMS-02 stand-alone system for collision monitoring and crash damage mitigation in machine tools from Marposs Corporation (Auburn Hills, MI) employs a ceramic strain sensor to detect irregularities in the production process by measuring elastic deformation in the range of 0.1 microns, and both slow and dynamically increasing forces which have damage potential. It then reacts extremely fast – in the range of one millisecond – by sending a stop signal to E-STOP, helping to alleviate or even eliminate machine crashes that can result in high repair costs and long down times. Compared to previous Brankamp (CMS-1) offerings, this CMS-2 is a very compact, single channel unit with 16 bits resolution, 25 kHz sampling rate, three operation modes and three limits per mode (warning, soft and hard stop outputs limits), stop-event data recording, and signal values log file.

Visualization of the data, analysis, and statistics, as well as the HMI, is realized by connecting an Ethernet cable to a Windows®-based industrial PC unit or the newest IPC4 dedicated monitor. This system is easy to install and can be retrofitted to existing machines. It does support several communication paths, such as discrete I/Os, Profibus-DP and Profinet. Operators of all skill levels can benefit from it immediately and without having to attend complex training courses. The system can also be expanded to work in conjunction with the Genior Modular monitoring system, achieving both collision detection and process monitoring simultaneously and visualizing the processes in parallel. To date, Brankamp CMS collision systems have been installed on more than 10,000 machine tools, handling systems and industrial robots worldwide.