Machining: Milling
Machining: Milling

Thanks to their flexibility, milling machines and machining centers are among the most commonly found machine tools. They range from simple 3-axis systems to complex multi-axis machining centers to hybrid machines which combine tools, for example, milling and laser machining. The main prerequisite for machining block-shaped workpieces: correct positioning and exact tool guidance at high speed. This is a challenge for the controlling measurement systems, since the degree of automation is continually increasing – especially when linked machines are used more and more for the production of high-volume parts.

Application examples

  • Monitoring end positions

    With BES inductive sensors

    The solution

    Do you need to monitor the traverse path of machine axes? You can choose from various options: Standard option with BNS mechanical position switches according to the principle of normally closed contacts connected in series, or non-contact with inductive sensors. If you use an incremental linear magnetic encoder system, the sensor signals can also be used for the reference point move.

    The features

    • Select from among various operating principles and choose your own best solution
    Monitoring end positions
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  • Monitoring tool clamping

    With BIP inductive positioning systems

    The solution

    Our inductive position sensors provide information about the correct clamping of the tool: unclamped, clamped with tool, and clamped without tool. Combined with our pressure sensors, the plausibility of the sensor signals can also be checked in hydraulic clamping systems via a second channel.

    The features

    • Exact, non-contact position detection
    • Impervious to contamination
    • Can be perfectly integrated even when there is limited space
    Monitoring tool clamping
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  • Decentralizing installation technology

    With BNI network modules

    The solution

    Compared with traditional star topologies, fieldbus blocks make the startup of the machine controller much simpler and cost-effective. Designed for all commonly used fieldbus systems, these blocks enable the use of many controller types while retaining the same wiring topology. And with IO-Link they are also ideal for the exchange of process, parameter and diagnostic data for the Industrial Internet of Things (IIoT).

    The features

    • Available in all common fieldbus technologies and with IO-Link
    • Very rugged versions, with high protection classes
    • For efficient field and process communication
    Decentralizing installation technology
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  • Safe Communication

    With BNI Safety over IO-Link blocks

    The solution

    The new safe I/O module is the first to connect automation and safety technology via IO-Link. It is simply connected to the IO-Link master. Since the system is open all the way to the sensor level, you can connect nearly any safety device.

    The features

    • An infrastructure for automation and safety technology up to PLe/SIL3 via IO-Link
    • Low maintenance costs in case of service thanks to comprehensive diagnostics and easy device replacement
    • Lower costs by using uniform M12 single-ended cordsets
    • Reduction of the required IP addresses
    • Standardized wiring concept, reliable safety guard locking devices can be connected directly
    Safe Communication
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  • Detecting the rotation angle on the C-axis

    With BML magnetic encoders

    The solution

    To determine the rotation along the Z-axis, rotary axis angles (A-, B-, C-) are increasingly used in addition to the main axes (X-,Y-,Z-). With our magnetic encoder, you can detect the rotation angle with high accuracy.

    The measuring principle provides you with generous leeway in the center of the axis, so there is more room for media such as coolants, the power supply, and signal lines.

    The features

    • Fast and highly precise with repeat accuracy
    • Small sensor head, fits in any recess
    • Sensor position eccentric to the axis: media flow-through is possible
    Detecting the rotation angle  on the C-axis
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  • Identifying tools in the magazine

    With BIS Industrial RFID systems

    The solution

    BIS C industrial RFID systems operating at LF (Low frequency) or BIS M at HF (High Frequency) ensure that your CNC controller in milling machines and machining centers always has the correct tool data available (number, diameter, length, number of cuts, etc.). Reliably identified and transmitted, these parameters also form the basis for high-quality tool asset management including service life monitoring.

    The features

    • High degree of flexibility for you with many different types of data carriers and read/write heads, including a read/write head that operates at both LF and HF
    • Technology-neutral processor unit – also suitable for large quantities of data
    Identifying tools  in the magazine
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  • Correctly associate and track workpieces

    With BIS Industrial RFID systems

    The solution

    Pallet systems with automatic external loading and unloading of workpieces reduce internal setup times to nearly zero so the machine can produce without interruption. At the point where workpieces are brought in, the BIS V frequency-neutral processor unit ensures correct association. This means you can process both large and small data quantities flexibly – depending on whether you favor decentralized or centralized data retention.

    The features

    • Automated workpiece management
    • Reduced scrap, increased productivity
    • High flexibility with all-frequency processor unit
    Correctly associate and track workpieces
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  • Displaying operating status

    With SmartLight LED stack lights

    The solution

    To reliably monitor the status of machines and systems, Balluff offers you SmartLight LED stack lights with IO-Link interface, which you can use to conveniently visualize the desired information. You can display important or critical machine conditions and use a color scale to simply read off tendencies and trends for physical variables. The SmartLight offers you three different modes which you can change on-the-fly.

    Changing colors is also possible without any mechanical modifications.

    The features

    • Versatile: various modes such as segment or stack light, level indication or bar graph, run light, and flexible mode can be configured
    • Application-flexible: multi-color, bright LEDs with a broad color spectrum – individually definable
    • Highly flexible: can be changed on-the-fly – no mechanical reconfiguration necessary
    • IIoT-ready – IO-Link makes them simple to install
    Displaying operating status
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Metalworking (PDF file)

Tool identification (PDF file)