An on-machine monitoring system for the failure state of the rotating tool and a detection method thereof are provided. The monitoring system includes a detector, a data processing controller, a tool data server, and a Hall current sensor. A tool diameter and a tool length are determined according to image sequences of a tool. A wear state and a breakage state of the tool are determined according to the tool diameter and the tool length. A spindle current signal is acquired by the Hall current sensor. And an edge chipping state and a breaking state of the tool are determined according to the spindle current signal.

A device for determining a dimension of a tool having a cutting edge includes a first light source configured to emit light parallel to a first axis, an image sensor which is associatable with a second axis extending orthogonally to the image sensor and an analyzing unit. The first axis and the second axis are inclined relative to each other. The device is configured such that the light emitted from the first light source is reflectable by the cutting edge of the tool in such a way that light spots arranged in a line on the image sensor are generatable by the reflected light. The analyzing unit is configured to determine positions of the light spots. The dimension of the tool is determinable based on the positions of the light spots.

A device and method used in a spindle or fixture to measure tool sizes. The device has two conical shapes that have precision machined surfaces. The device's face has a precise size which is the same nominal size as that of a material removing tool. The device's shaft allows for concentric and precision fastening of the device to a spindle or a fixture. The nose of the device is located on the end of the larger of the two conical shapes which is visible exposed when mounted and used. The end of the device is at the end of the smaller of the two conical shapes which is hidden after mounting. The combination of using the device and method will allow more accurate programming of machine tools which in turn will provide higher quality results on machined work pieces and reduced machining cycles.

A non-contact tool setting apparatus, suitable for use with machine tools and the like, is described in which a transmitter emits light that is received by a receiver. An analysis unit is provided for analysing the light received by the receiver and generating a trigger signal therefrom. The receiver includes an imaging sensor, such as a CMOS or CCD sensor, having a plurality of pixels. The analysis unit generates the trigger signal by analysing the light intensity measured by a first subset of the plurality of pixels. This analysis may involve, for example, determining a resultant received light intensity or performing edge detection. The non-contact tool setting apparatus can thus emulate the operation of a laser based non-contact tool setting apparatus whilst also permitting imaging of cutting tools.

A machine tool improving measurement accuracy of a machined workpiece diameter. A machine tool comprises a displacement sensor mounted on at least one of a guide bush and a spindle supporting unit. The machine tool further comprises a calculating unit which calculates a diameter of the machined workpiece based on a measurement value of the machined workpiece by the displacement sensor. The spindle is movable back and forth in an axial direction. The spindle is retracted after machining to bring a machined portion of the workpiece to a predetermined measurement position in the axial direction to allow the displacement sensor to measure the machined portion.

A method for checking a tool uses a device with a light emitter for beam emission for tool scanning and with a beam receiver for beam reception and for outputting a shadow signal; and an evaluation unit for processing the shadow signal; rotation of the tool; moving the tool until it reaches a starting position in which the blade dips into the beam and shades this such that a threshold of a range of the evaluation unit is reached or undershot; moving the tool, starting from the starting position, out of the beam and registering the shadow signal; ascertaining that the shadow signal for a cutting edge does not fall below the lower switching threshold or exceed the upper switching threshold such that a shadow signal lies above the lower and below the upper switching threshold; wherein the feed is determined in proportion to a measurement range.

A machine tool is provided with a main shaft configured to have a tool fitted to a distal end portion thereof, a tool magazine for holding a plurality of tools, a tool exchanging arm for exchanging tools between the tool magazine and the rotary main shaft, and a table for attaching a workpiece, wherein the machine tool machines the workpiece by causing the main shaft and the table to move relative to one another in accordance with a machining program, and wherein the machine tool: is provided with an image capturing device for capturing an image of the tool fitted to a tool holder, and an interference checking device which uses the machining program, and shape data relating to the workpiece, the tool, and the machine tool to simulate machining before machining is carried out, to check for the presence or absence of interference between at least the tool and the workpiece; and acquires the shape data relating to the tool from the interference checking device, generates a two-dimensional tool model from the acquired shape data relating to the tool, compares the two-dimensional tool model with an image of the tool captured by the image capturing device, and determines that the tool is invalid if an amount of displacement between the two-dimensional tool model and the image data is equal to or greater than a prescribed threshold.

A machine tool improving measurement accuracy of a machined workpiece diameter. A machine tool comprises a displacement sensor mounted on at least one of a guide bush and a spindle supporting unit. The machine tool further comprises a calculating unit which calculates a diameter of the machined workpiece based on a measurement value of the machined workpiece by the displacement sensor. The spindle is movable back and forth in an axial direction. The spindle is retracted after machining to bring a machined portion of the workpiece to a predetermined measurement position in the axial direction to allow the displacement sensor to measure the machined portion.

A processing unit for measuring and controlling a rotary-driven tool, wherein the processing unit is connectable to a light barrier arrangement, which comprises a light-transmitting unit and a light-receiving unit, wherein the processing unit is configured to receive from the light-receiving unit signals that are at least approximately proportional to shading generated by the rotary-driven tool and/or at least one cutting edge of the rotary-driven tool at a first measuring position. The processing unit is further configured to evaluate the signals received and to transmit control signals to the light barrier arrangement, wherein the evaluation of the signals received by the processing unit comprises the following steps: determination of an interference signal component and/or a useful signal component of the received signal; and provision of information about the useful signal component, the interference signal component and/or the received signal for forwarding to a numerical controller of a machine tool.

A non-contact tool setting apparatus, suitable for use with machine tools and the like, is described in which a transmitter emits light that is received by a receiver. An analysis unit is provided for analysing the light received by the receiver and generating a trigger signal therefrom. The receiver includes an imaging sensor, such as a CMOS or CCD sensor, having a plurality of pixels. The analysis unit generates the trigger signal by analysing the light intensity measured by a first subset of the plurality of pixels. This analysis may involve, for example, determining a resultant received light intensity or performing edge detection. The non-contact tool setting apparatus can thus emulate the operation of a laser based non-contact tool setting apparatus whilst also permitting imaging of cutting tools.