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Sensing roller: Wear & Maintenance

Sensing rollers detect the surface, contours or edges of workpieces


  • Recording of switching times at the beginning and end of workpieces during their machine cycle
  • In conjunction with a copying unit: maintaining a defined distance between tool and workpiece

Quality deficiency, observation

  • Irregular milling pattern
  • Uneven, deeper milling strokes

Possible causes

1. Milling chips lie on the workpiece and are traversed by the sensing roller

  • Remedy: Check extraction of the preceding milling units

2. Contamination of the running surface of sensing rollers

  • Glue adhesion, chips
  • Check and optimise glue quantity
  • Check extraction

3. Unevenly worn contact surfaces of sensing rollers

  • See pictures 1, 2
  • Sluggish bearing or blocked sensing roller rotation
  • Impurities and chips brake or block the travel of the sensing roller
  • Roller wears out selectively and tool engages deeper into the workpiece at these points

Test possibility/ Remedy

  • Check the sensing rollers and wipers regularly, check for smooth running and clean
  • In case of wear and tear, the roll must be replaced.


punktuelle Abnutzung der Tastrolle infolge Blockierung (1)
BRANDT, 2016
verklebte, verschmutze, verstopfte Abstreifer blockieren Tastrolle (2)
BRANDT, 2016
Ausbrüche an Gummibeschichtung und Werkstückkante
BRANDT, 2007
Tastrolle Vergleich neu - verschlissen
BRANDT, 2007