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HEIDENHAIN TOOL BREAKAGE DETECTION

HEIDENHAIN, a leading manufacturer of metrology and CNC control technologies, offers advanced solutions for efficient tool monitoring, control, and condition detection directly inside the machining environment. With products such as the TD 110 tool breakage detector, VT 121 and VT 122 vision systems and VTC inspection software. HEIDENHAIN responds to increasing industry demands for automation, precision, and process reliability.

TD 110

  • High-performance tool breakage sensor
  • Inductive, non-contact detection
  • Detects tool breakage even during rapid movement past the sensor
  • Compact and rugged housing
  • Suitable for inspecting HSS and carbide micro-tools (down to ∅ 0.4 mm)

ENHANCED PROCESS RELIABILITY

The TD 110 significantly reduces scrap due to undetected tool breakage and prevents secondary damage to the machine or workpiece. Because it requires no teach-in procedure, it is ideal even for one-off jobs involving micro-tools.

REDUCED OPERATING COSTS

The TD 110 operates without compressed air, directly lowering total cost of ownership (TCO). It also requires only a single cable and is maintenance-free, further reducing operational costs.

MINIMIZED MACHINE DOWNTIME

The TD 110 checks each tool up to six seconds faster than laser-based systems. When combined with the TNC7’s process monitoring, machine idle time can be reduced even further. The inductive sensor works at the current spindle speed and integrates smoothly into the workflow.

RETROFIT CAPABILITY

The TD 110 can be retrofitted to any CNC control system. For machines with HEIDENHAIN TNC controls, remote support for installation is available. Its compact, non-intrusive form simplifies integration. Depending on the setup, the same cable type can be used for both the TD 110 and TT 160 probe.

VT 121, VT 122

Vision Systems for Tool Measurement and Inspection

  • Two cameras with ring and side lighting
  • VT 122: additional illumination for in-process measurement
  • Compressed-air connection for cleaning the tool and lenses
  • System control and tool analysis via VTC software
  • Automation enabled through VTC cycles
  • Interface: Gigabit Ethernet
  • Protection rating: IP66/IP68

RUGGED AND COMPACT DESIGN

With IP66/IP68 protection and protective lenses, these systems are highly durable, space-saving, and easy to service. They are designed for in-machine installation, capable of withstanding harsh industrial environments.

THREE-IN-ONE FUNCTIONALITY

These camera systems automatically capture high-quality images for effective tool inspection, combining three functions into one system:

  • Tool measurement
  • Microscopic tool inspection
  • Tool wear monitoring

TOUCHLESS IN-PROCESS MEASUREMENT

Non-contact measurement enables safe inspection of even delicate tool edges.

  • VT 122 supports tool presetting and in-process control for end mills, ball-nose cutters, and drill bits with a minimum diameter of 1 mm.
  • VT 121 checks tools for breakage.

PANORAMIC OR CLOSE-UP IMAGING

Both systems capture:

  • Detailed images of individual cutting edges
  • Panoramic views of the entire tool circumference

Lighting angles can be adjusted virtually to optimize illumination of specific teeth. Tools can also be imaged from below for tip inspection.

VTC SOFTWARE – ADVANCED TOOL INSPECTION PLATFORM

The VTC (Visual Tool Check) software can operate automatically even during unattended production, using cycles integrated into TNC7 and TNC 640 controls. Through its interface with the TNC tool table, the software can automatically lock tools as needed to ensure process reliability.

TOOL WEAR MEASUREMENT

After capturing magnified images of individual cutting edges or panoramic views of the tool’s circumference, the VT software allows precise flank wear measurement. This data can be used to:

  • Create inspection reports
  • Automatically lock worn tools via the CNC interface, preventing further use

VERSATILE PANORAMIC IMAGING

Panoramic images allow virtual lighting of each edge from various angles, improving:

  • Visibility of wear
  • Documentation over time
    These insights can reveal opportunities to optimize cutting parameters and NC programs.

TOOL STATUS ASSIGNMENT

For tools with multiple cutting edges, VTC provides:

  • Quick navigation between images
  • Zoom functionality for detailed inspection
    Using a traffic light system, tools can be assigned a status (green, yellow, red). “Red” tools are automatically locked in the TNC tool table.

WEAR TRACKING OVER TIME

To ensure consistent comparisons, VT software can capture images of the same edge, at the same position and lighting conditions. This makes inspections faster and more reliable than traditional lab-based microscopy.

IMAGE DATABASE MANAGEMENT

After defining camera angles in the imaging cycle, the software:

  • Automatically generates tool images
  • Sorts them in the image database based on tool table designations
    Users can further customize image grouping via cycle parameters.

SERIES COMPARISON TOOL

A dedicated comparison feature displays side-by-side images of the same edge across time, helping users visually track wear.
With the image overlay function, users can even generate heatmaps that highlight wear patterns over time.

LINK TO THE OFFICIAL WEBSITES

TD 110, VT 121, 122, VTC