Milling
Milling

Reduce errors when machining workpieces with a high degree of automation

Thanks to their flexibility, milling machines and machining centers are among the most commonly found machine tools.

Their range of types extends from simple 3-axis-systems to complex multi-axis machining centers to hybrid machines that combine, for example, milling and laser machining.

The main pre-requisites for machining workpieces: Correct positioning and exact tool guidance at high speed. These requirements present a challenge for the controlling of measuring systems, because the degree of automation is also constantly increasing especially when machines are interconnected and used for the production of mass production parts.

Application examples

  • Monitoring tool clamping

    Check tool clamping with positioning & pressure sensors

    The solution

    BIP inductive positioning systems from Balluff can supply vitally important information about tool clamping: Unclamped, clamped with tool, clamped without tool. Combined with our BSP pressure sensors, the plausibility of the sensor signals can also be checked in hydraulic clamping systems via a second channel.

    The features

    • Verify tool clamping: unclamped, with tool, without tool, wrong tool
    • Secondary verification of tool clamping with pressure sensors
    Metal machining, checking tool clamping
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  • Machine Mount Distributed I/O

    Universal, smart, easy and Industry 4.0 ready

    The solution

    With machine mount I/O blocks, the commissioning of the machine controller for the individual sensor is decidedly simpler and more economical than with the classic wiring methods. Because the blocks are designed for all standard industrial ethernet & fieldbus systems, you can use them with a variety of controllers.

    Moreover, via IO-Link, the blocks are a perfect fit for Industry 4.0 and Industrial Internet of Things (IIoT) applications. This is because they enable the exchange of parameters, process and diagnostic data and provide for easy scaling of the control architecture.

    The features

    • Simpler and more cost-beneficial commissioning than in the case of classical hard wiring
    • Compatible with a variety of controller brands
    • Predisposed for Industry 4.0 & IIoT
    Metal machining, commissioning of machine controllers
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  • Monitoring end stop positions

    Reliably checking linear travel of machine components

    The solution

    When trying to check the travel of machine shafts, you have two options: Classic applications utilize BNS mechanical position switches requiring physically switching the sensor or utilizing contactless BES inductive sensors.

    Newer applications utilize our incremental BML magnetic encoder, the sensor signals are sometimes also used for reference point runs.

    The features

    • Physically or contactlessly check travel of machine shafts
    • Use of the sensor signals for the reference point travel with an incremental magnetic encoder
    Metal machining, commissioning of machine controllers
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  • Detecting the rotation angle on the C-axis

    High-precision detection of the angle of rotation with magnetic encoder

    The solution

    In order to monitor the rotation along the Z-axis, auxiliary axes (for example, C) are also used increasingly in addition to the main axes X, Y and Z.

    Our BML magnetic encoder is used for high-precision detection of the angle of rotation. Its measurement principle enables clearance in the center of the axis. As a result, media such as cooling lubricants as well as the power supply and signal lines can better be fed through.

    The features

    • High-precision detection of the angle of rotation
    • A lot of clearance in the center of the axis – better feed through media, power supply and signal lines
    Metal machining, commissioning of machine controllers
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    Have any questions? Please give us a call or send us an email. We look forward to hearing from you.

  • Identifying tools in the magazine

    Reliably store tool data from the pre-setter, usage and maintenance

    The solution

    BIS C industrial RFID systems in LF (low frequency) or BIS M in HF (high frequency) ensure the correct tool data (number, diameter, offsets, length, number of cutting edges, ...) are made available to the CNC controller in milling machines and machining centers.

    Reliably identified and transferred, these parameters are the basis for optimized, high-quality tool management allowing for downtime monitoring.

    The features

    • Correct tool data for CNC control
    • Optimized, high-quality tool management with downtime monitoring possible
    Metal machining, optimized tool asset management
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  • Matching and tracking workpieces

    Automated workpiece movement for continuously producing machines enabled by RFID

    The solution

    Pallet systems with automatic external loading and unloading of workpieces reduce internal setup times so that the machine can increase cutting time.

    Our BIS M 13.56-MHz HF system has established itself as the standard for reliable assignment and tracking with RFID. The system reads and writes key data to the code tag like databolts attached directly to the pallet or the workpiece.

    The features

    • Setup times for workpiece changeover reduced
    • Reliable assignment and tracking with RFID
    • Read and write key data storage media coded on tags or databolts attached to the pallet/workpiece
    Metal machining, optimized tool asset management
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    Have any questions? Please give us a call or send us an email. We look forward to hearing from you.