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IT Secure automated production with Montronix before it gets expensive
When no human is standing in front of the machine, technology must take over. Our sensor technology secures your automated production in such a way that errors are not only detected but actively prevented. It doesn't matter whether it's loading, machining, or tool wear: Montronix provides the system that understands and protects processes.
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When no one is watching, what the system detects matters
Automated production is the answer to staff shortages and rising cost pressure. Workpieces are loaded, machined, and removed without human intervention. But that makes the process vulnerable. If an error occurs, it often goes unnoticed—until it's too late.
A misgripped part, a damaged cutting edge, or unstable feed not only leads to scrap but also damages the spindle, fixture, or tool. That costs time, money, and trust in production. That’s why automated production needs monitoring that does more than just measure. It must truly understand the process.
Montronix systems understand your production
Our sensors detect what’s really happening. They compare each machining process with a reference process. At the slightest deviation—too much force, an unexpected vibration, or an unusual cutting pattern—the system reacts. Instantly.
What is monitored
- Machining and cutting force at tool and spindle in real time
- Vibrations and collisions during machining
- Tool condition, breakages, and wear indicators
- Movements of gantry, robot, or linear axis
- Gripping processes on workpiece and fixture
Each piece of information is processed live. And if something doesn’t fit, the process is stopped or an alarm is triggered. All without human intervention and without delay.
Contact us nowLoading and unloading: The first weak point in automated workflows
Detect collisions during movement
Whether a workpiece hits the fixture or a gripper fails to release the part, a collision can cause massive damage. A vibration sensor on the axis detects this disturbance immediately. The control system receives a signal in less than a millisecond and stops.
Reliably detect misgripping
Strain sensors on the gripper arms check whether the workpiece has been correctly gripped. If it’s not positioned as intended or not held with the planned force, the system reports the error. This ensures that the handover to the machine works smoothly.
Workpiece machining: Monitoring while the process runs
Power Sensor PS200-NG
The PS200-NG measures active power via 3 Hall sensors directly on spindle and feed drives. Even the smallest changes in force progression over time are detected and reported to the machine control within 1 microsecond—for example, due to dull cutting edges or unsuitable material. This deviation is reported immediately. You avoid scrap and detect tool wear long before dimensional accuracy suffers.
Even incorrect pre-machining of workpieces is detected—whether the power is too low (e.g. pre-drilled hole diameter too large for threading) or too high (e.g. diameter too small). If there’s too much stock allowance, power demand during drilling is triggered earlier than with good parts. If too little, it’s triggered later.
Highlights:
- Responds to ±0.25% power change
- Works independently of control system
- Direct connection via M8 plug
- Ideal for series production and small milling tools
Vibration Sensor Pulse Plus
The Pulse Plus is a 3D sensor that detects vibrations in all three spatial axes (X, Y, Z). If the vibration behavior of a tool changes—due to emerging wear, imbalance, or workpiece anomalies—the sensor reports the change in real time. This allows you to detect deviations before damage occurs. It’s especially effective for collisions and bearing damage.
Highlights:
- MEMS technology with 3-axis measurement
- Data rate up to 26,667 values/second per axis
- Mounting via magnetic base or screw thread
- Ideal for milling centers, grinding machines, robots
Strain Sensor Strainlink
The StrainLink250 DA is based on strain gauge technology. It measures surface strain directly on the machine structure or on gripping systems at the gripper finger. It detects stress early and protects processes from damage. The integrated strain gauge film converts tiny material deformations from pressure/tension/torsion into an analog signal. The sensor is suitable for static and dynamic applications, regardless of machine type.
Highlights:
- Compact size with full performance
- Robust housing for industrial use
- Maintenance-free and durable
- Direct integration possible, independent of control or machine manufacturer
Force Sensor RetroBolt
The RetroBolt measures actual cutting force at the tool. If the force deviates from the reference—due to dull cutting edges or chip jamming—the system triggers an alarm. You can integrate the sensors directly into existing machines, for example under the screw connection of the turret. Especially in turning processes, RetroBolt provides highly precise information about tool load and makes early signs of tool wear or micro-breakouts visible.
Highlights:
- Direct mounting under existing screw points
- High resolution even for micro-breakouts
- Can be combined with Spectra ONE for analysis
- Suitable for multi-spindle and special-purpose machines
Overview of Components for Tool Wear Detection
How the Protection Mechanism Works
Initially, a reference part is machined. The system records all force, vibration, and power data. These form the baseline. From that point on, the system compares every new cycle with the reference process. If the signals no longer match, the system reacts immediately.
The reaction is determined by the operator. It can be a machine stop, a warning light, an email alert, or automatic forwarding to support. The response is fully customizable.
Your Benefits with Montronix in Automated Production
Less Scrap
The system detects faulty processes before a workpiece is completed. Only good parts leave the machine.
Longer Tool Life
By monitoring forces and vibrations, tools can be replaced in time before causing damage.
Reduced Machine Downtime
Collisions that would otherwise lead to spindle or bearing damage are detected within one millisecond and reported to the control system to minimize damage. This saves repair time and money.
Consistent Quality with Changing Personnel
Even when no one is at the machine or operators change frequently, the system ensures consistent quality.
Compatible with Older Machines
Our systems are independent of control system, year of manufacture, or machine type. Retrofit projects are easily possible.
Typical Application Areas
Our systems are suitable for all industries involving machining, automation, or high quality standards. Wherever tools are used and their condition is critical.
- Loading portals and robots benefit from precise detection of empty gripping or failure to release due to unopened grippers/fingers.
- Machining centers, milling machines, and lathes ensure machining quality in series production and with changing materials.
- Special-purpose machines receive customized sensor solutions for specific requirements.
Our Services for Your Automated Production
- System Consulting and Design
We analyze your processes, identify suitable sensors, and configure a system tailored to your application. - Pilot Project with Trial Setup
You receive a complete solution for testing in your own machine. Experience the functionality live in your production. - Installation and Commissioning
Our experts support you on-site or remotely. Installation is done without long downtimes and without interfering with the control system. - Training and Support
We train your staff and are available for questions at any time—even for later expansions or adjustments.
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Want to make your automated production safer? Detect errors early, avoid downtime, and ensure quality? Then write to us or give us a call. We’ll show you how Montronix systems can secure your processes.
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