Senso 3000 Hydraulic Tool Holder Force Gauge

The SENSO 3000 is a specialized tool for verifying correct operation of hydraulic tool holders. For workholding collet force gauges, please see our ForceCheck collet force gauges.

SENSO 3000 determines the clamping force of the hydraulic chuck via a pressure sensitive plug gauge. The entire length of the plug gauge is clamped in the hydraulic chuck so that when tightening the clamping screw the clamping pressure of the chuck is optimally applied. The clamping force measuring instrument displays the clamping force as an absolute measurement value on the one hand and as a percentage clamping force in relation to a reference value that can be set individually on the other. This way, SENSO 3000 can be adapted to customer specific application conditions and requirements.

The clamping force measuring instrument is supplied with a plug gauge for the respective clamping diameter as well as a carbide proofing bar for calibration purposes and a CR 2430 type battery – all in a sturdy and handy case.

Collet Force Gauges

ForceCheck Hydraulic Tool Holder Force Gauges

Hydraulic tool holders are an excellent ultra-low option with added benefits such as vibration damping and ease of use. One of the major challenges with hydraulic holders is determining if they are still functioning correctly over time. Failure of the hydaulic holding mechanism is often not apparent until cutter slippage occurs, potentially causing damage to both the holder and a scrapped workpiece.

ForceCheck hydraulic tool holder force gauges provide a quick and reliable way to verify a tool holder is still operating correctly. The sensor measures the force at the center of the hydraulic sleeve.

Using the gauge is as easy as inserting the sensor in the hydraulic holder. Once the actuation piston compresses the hydraulic fluid in the expansion sleeve, the resulting force is shown on a handheld digital display. The measured force can be compared to a new or known-good hydraulic tool holder.

Hydraulic Collet Force Application Worksheet

Download PDF for worksheet.

Workholding Collet Drawbar Force Gauge

ForceCheck collet force gauges measure the drawbar pullback force of a 5C, 16C, or 20C collet workholding system. Measurement of collet drawbar force provides an easy way to ensure correct force from machine to machine, or between setups for different parts.

Tool Holder Taper Inspection Gauge

Available for all steep taper tool holder sizes (20, 30, 35, 40, 45, 50, 55, 60)

The tool holder inspection gauge is designed to inspect tool holder taper diameters for wear and other potential problems. Verifying tool holder tapers are correct can help to maximize spindle life and improve part finish.

Please note that the taper inspection gauge will only check diameter on two planes along with taper angle. The gauge will not detect nicks or localized damage to the taper. We recommend using series 430.110 taper sleeve gauges in conjunction with the taper inspection gauge for this purpose.

The tool holder taper inspection gauge includes the Fixture Base and two Indicators (0.002mm or 0.0001 inch resolution). An optional 430.110 certified Taper Master is strongly recommended for zeroing the Indicators. If a master is not available, a knowngood tool holder can be used in place of the master.

ForceCheck Workholding Collet Force Gauge

ForceCheck collet force gauges provide a quick and easy way to check force on collet workholding systems.

Applications for ForceCheck workholding collet force gauges include:

-Comparison of holding force between machines, allowing for consistent and repeatable production results regardless of mechanism (manual, hydraulic, or pneumatic)
-Periodic verification to assess if preventive maintenance is needed
-Establish correct holding force for running a particular part or job
-Determine optimal holding force for thin-wall, rings, and other parts sensitive to damage or distortion when machining


A sensor is needed for each diameter to be measured. A ForceCheck base set with display is needed to display results (order separately).
Sensors are also available in low-force versions. Contact us for further information.

Application Information: ForceCheck Workholding Collet Force Gauge

<strong>Collet Force Operating Principle</strong>
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We often get questions on the operating principle of the sensors. First a bit of explanation on what is really happening with a collet
- a collet generates a force over a cylindrical area, which is ultimately a pressure. In practice, that pressure often varies at different locations along the axis of the collet. For example, with a 5C or collet that is segmented at the front and solid in the back, the pressure will be considerably higher to the front.
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In measuring force, our sensor measures at a single axis perpendicular to the axis of the collet. What is displayed is a "vector force" on that axis in Newtons or Pounds-Force. This is a snapshot of the whole collet that simplifies what is really happening but it provides a quick reference that will allow a user to compare different setups, machines, etc.
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Because of the way we&rsquo;re measuring, the number displayed by the sensor generally can&rsquo;t be directly correlated to the pressure gauge "on the back of the machine" due to the long chain of hydraulic/pneumatic/mechanical links between them.
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<strong>Collet Force Accuracy/Repeatability</strong>
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Several factors influence repeatability: friction in the system, mechanical advantage of the closer mechanism, inconsistencies between clamping cycles, collet diameter tolerances, sensor insertion orientation, etc. Because of the large number of variables, a user shouldn&rsquo;t expect highly consistent repeatability. Generally we see something in the +/-10% but it can sometimes be significantly higher as the variables mentioned can fluctuate between clamping cycles.
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We recommend considering the collet force gauge as a comparison tool. For example, comparing the collet force between two machines with automatic systems. Another example would be variance in holding force between operators on a manual collet closer. Less important is the actual number measured; more important is a comparison between the numbers. Variance can be expected due to the multitude of variables at play: +/-10% is likely ok whereas 2x the force would be significant.
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<strong>Common Use Cases for Collet Force Gauges</strong>
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-<strong>Monitoring for changes in force over time:</strong> Changes can indicate mechanical problems, need for lubrication, etc.
-<strong>Comparison between machines:</strong> To ensure consistent production, multiple machines running the same part can be adjusted to approximately the same force.
-<strong>Job setup:</strong> Establish a "known good" holding force for running a specific job that can be easily re- set up next time the job is run.
-<strong>Establish force for delicate parts:</strong> Holding force for thin-wall or other sensitive parts can be a balancing act between having sufficient holding force and distorting parts. The collet force gauge can help to establish an optimum force.


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<strong>Contact us with questions</strong>
Please contact our Applications Engineering Team at 815 962-5600 with questions on your collet system. We are happy to assist in determining if our collet force gauges will help for your specific workholding challenges.
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Tool Holder Drive Key Tool Taper Gauges

Available for HSK 32, 40, 50, 63, 80, 100, 125, 160

HSK Tool Holder Taper Inspection Gauge

Designed to detect tool holder taper wear in seconds.

The tool holder taper inspection gauge includes two Fixture Bases, two 0.001mm Indicators, and a carrying case. An optional 410.148 certified Taper Master is strongly recommended for zeroing the Indicators. If a master is not available, a known good tool holder can be used in place of the master. Click the Details Tab for more information.