The AE-1000 is an acoustic emission (AE) monitoring system that mounts on grinding machines to perform two critical functions: crash detection and gap elimination. Using high-frequency acoustic sensors bonded to the machine structure, it listens for the characteristic stress-wave signatures produced when the grinding wheel contacts the workpiece — or collides with a misloaded part, fixture, or tooling. Detection and output response occur in under 1 millisecond, enabling the CNC to retract the wheel before damage propagates.

How does acoustic gap elimination reduce cycle time?

Without gap control, a grinding machine must approach the workpiece at a reduced feed rate through the unknown air gap — a safety margin that adds unproductive seconds to every cycle. The AE-1000 detects the initial wheel-to-workpiece contact at the sub-micron level within 5 milliseconds and outputs a trigger signal to the CNC to end the gap phase immediately. Eliminating this air-grinding time typically reduces overall cycle time by 10–20%, while the gap trigger ensures the wheel approaches at full speed with no risk of overshoot.

What frequency bands are available and how are they selected?

Four user-selectable frequency bands — 50–170 kHz, 160–280 kHz, 270–390 kHz, and 380–500 kHz — allow the AE-1000 to be tuned to the specific acoustic signature of different grinding operations. Lower bands suit large wheel-workpiece contact areas in cylindrical grinding, while higher bands isolate the sharp transient signatures of diamond dressing and small-contact-zone processes. A 0–77 dB gain control provides further signal conditioning. The OLED graphical display provides real-time waveform visualisation for threshold setup and diagnostic checks.

How does the AE-1000 interface with the CNC?

The system connects to the machine CNC or PLC via opto-isolated hardwired I/O, ensuring galvanic isolation from the machine's control circuits. A USB 2.0 port provides configuration access from a PC. Crash and gap detection signals are delivered as discrete outputs; an auto-scaling 0–10 VDC analogue output reflects the real-time AE signal amplitude for process monitoring and data logging.