Ever shorter delivery times and smaller batch sizes combined with increasing demands on quality and precision are presenting the manufacturing industry with major challenges. In order to continue to produce economically, quickly, reliably and flexibly, the answer in many areas is Industry 4.0. "The more automated a manufacturing process is, the more data must be automatically recorded, transferred and ultimately evaluated from the application. This also applies to workpiece clamping. It is an important factor for productivity, as the tools and machines used can only deliver full quality and performance if the parts to be machined are clamped reliably, reliably and precisely," says Bernd Janner, Sales Manager at Erwin Halder.

Check the exact position of the workpiece

The compact monitoring unit consists of a height-adjustable, blue anodized aluminium sleeve with a switch sensor attached to the outside. Thanks to its design in accordance with protection class IP67 and a special sheathing on the connection cable, it can be used in the machine room without hesitation. The base body of the unit, made from burnished heat-treated steel, can be quickly and easily screwed into all standard fixture systems with an M8 or M12 thread. The respective support element is then screwed into the sleeve. This means that existing Halder support elements can continue to be used. The support elements are available in case-hardened steel with a flat, crowned or ribbed support surface and in plastic (PEEK) with a flat support surface.

When the component is placed in the device on the support element, the sensor automatically checks whether the workpiece is in a specific position. The system can be extended to monitor several positions. If the workpiece is in the correct position, the sensor transmits an electrical signal, which is simply transmitted via a cable connection.

If the workpiece is positioned correctly, the sensor transmits an electrical signal, which is simply transmitted via a cable or optional wireless connection. © Erwin Halder

Models with signal cable and with radio transmission

"As in most cases there are only limited possibilities in the machine room to run a signal cable to the outside, we offer an optional radio module for the monitoring unit," says Bernd Janner. A transmitter and receiver with antenna are also required for the radio connection. The transmitter is placed anywhere in the engine room and connected to up to four sensors via a socket cable. It transmits the signal to the receiver outside the machine - depending on the material and thickness of the machine cladding, safely over 40 meters and further. Installing the radio module is also very simple. No complex programming is required; each scanning unit simply needs to be registered using the teach function with just a few button presses.

Space problems are not an issue, as the scanning unit is comparable to the support elements, only slightly higher. The radio unit is also very compact and can be placed slightly outside the fixture without interfering with the workpiece. "The cable, switch and receiver are specially designed for the harsh conditions in a machine tool, so there is no risk of short circuits. With IP67, the unit is dustproof and protected against temporary submersion," adds Bernd Janner.

There are several conceivable options for evaluating the electrical signal from the monitoring unit. For example, it can be connected directly to the machine control system, via additional software to a PC or other evaluation devices with potential-free relay outputs. The release for processing is then also controlled there.