Collision Monitoring for Machine Tools: When Milliseconds Matter

A crash in the machine tool often lasts only a fraction of a second. But it is precisely at this moment that it is decided whether only a tool needs to be replaced or the spindle will be out of service for weeks. With collision monitoring from Montronix, you react faster than any control system and sustainably protect your investment.

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Why Collision Monitoring is Essential

Collisions are rare, but when they occur, the damage is enormous. An incorrectly inserted workpiece, a faulty machining program, or a wrong tool number is enough. The machine control often interprets the resistance as a normal process deviation, such as a changed cutting force or uneven material. While the control is still trying to compensate, the tool continues to move and increases the crash.

The result is blocked axes, damaged bearings, or even a destroyed spindle. In addition to high repair costs, there are unplanned downtimes, delivery problems, and production losses. Collision monitoring reduces exactly this risk, as it works independently of the machine logic and reacts faster than any control system.

How Collision Monitoring Works in Machine Tools

Montronix systems are based on physical measurement. Our sensors register real vibrations and accelerations in three axes simultaneously. Even the smallest deviations from the normal state trigger a signal that is immediately transmitted to the evaluation unit. This unit is firmly connected to the emergency stop input of the machine.

The reaction time is less than one millisecond. For comparison: CNC controls usually take between 10 and 100 milliseconds to react to a deviation. During this time, the tool continues to move and may cause irreparable damage.

With Montronix collision monitoring, the machine stops in time. In many cases, it remains at a tool breakage. Spindle, fixture, and workpiece remain intact, and production can continue after just a few minutes.

The Components of the Montronix Solution

Pulse Plus

The Pulse Plus is a MEMS sensor that measures accelerations in three axes. It detects the finest vibrations and is suitable for applications with a wide frequency range, such as machining centers and grinding machines. The housing is robustly encapsulated and protected to IP67. Mounting is possible with a screw or magnetic foot.

Advantages of Pulse Plus

Detection of the smallest movement deviations
Wide frequency range for versatile applications
Robust and easy to mount

Pulse M12 Plus

The Pulse M12 Plus offers the same performance as the Pulse Plus, but in a compact M12 fine-thread screw form. It is ideal for tight installation situations, such as directly on spindles or in axis modules. It is also encapsulated, IP67 protected, and designed for continuous industrial operation.

Advantages of Pulse M12 Plus

Space-saving design in M12 screw form
Identical measurement performance as Pulse Plus
Easy integration into existing machines

IBU Plus and IBU Plus NX

The evaluation units IBU Plus and IBU Plus NX are the heart of collision monitoring. They compare the sensor signals with limit values and trigger an immediate stop in case of deviation. The systems work independently of the control system and can be retrofitted without any problems. The difference is that the IBU Plus is designed for one sensor, while the IBU Plus NX can evaluate up to 4 sensors simultaneously.

Advantages of IBU Plus / IBU Plus NX:

Real-time analysis of sensor signals
Flexibly adjustable limit values
Suitable for new machines and retrofit

Dull Collision

A dull collision occurs when an object is hit at very low speed. No vibration is generated here, only pressure on the machine structure, which is why a dull collision is best monitored with a Strainlink system. The pressure on a surface is measured very sensitively using strain gauges. The sensitivity can be set so finely that even the pressure of a finger on a steel beam is detected. This type of monitoring is much less common in practice and is usually used as a supplement. With an IBU Plus NX, for example, two Pulse Plus vibration sensors and two SLA NG amplifiers for up to four Strainlink sensors can be connected simultaneously.

Advantages of Strainlink Sensors with SLA NG Amplifier

Detection of gentle pressures at slow movements
High sensitivity for fast detection
Robust and retrofittable at any time

Spectra ONE

Spectra ONE extends classic collision protection with process monitoring and documentation. The system records all sensor events, displays data in real time, and supports condition-based maintenance. Especially in series production, it provides valuable information for quality assurance.

Advantages of Spectra ONE

Complete documentation
Real-time visualization
Preparation for predictive maintenance

Spectra ONE can be seamlessly combined with IBU Plus, Pulse Plus sensors, and other components from the Montronix portfolio. It is particularly suitable for systems with high quality requirements or for preparation for predictive maintenance.

The Advantages of Collision Monitoring at a Glance

Avoid Damage

The most important advantage is the protection of spindles, bearings, and fixtures. By reacting in less than a millisecond, the feed is stopped immediately. In many cases, it remains at a tool breakage, while the valuable machine parts remain undamaged.

Reduce Downtime

A spindle breakage quickly leads to several weeks of downtime. With collision monitoring, the machine remains operational after a crash and can usually be back in operation after just a few minutes.

Independence from Control System

The systems work independently of CNC controls. Whether Siemens, Fanuc, or Heidenhain, it does not matter. This means that the solution can be used in almost any machine.

Easy Integration

The sensors can be attached directly to the critical point of the machine. Mounting is possible with a screw or magnetic foot, and connection to the evaluation unit is via standard connectors.

Accurate Documentation and Analysis

All events are recorded. This allows causes to be traced afterwards. Operators can learn from the data and optimize their processes in the long term.

Planning Reliability for Production

If long repair downtimes are avoided by collision protection, delivery times can be reliably met. Customer orders can be fulfilled as planned, which strengthens the trust of business partners.

Added Value for Everyday Production

With collision monitoring you not only protect your machines, but also your delivery capability. Customer orders can be reliably fulfilled because unplanned downtimes are minimized. Tools are optimally used, scrap is reduced, and processes are stabilized.

Especially in unmanned operation, monitoring ensures safety. While robots load and workpieces are automatically clamped, the system intervenes in the background. It reacts precisely at the moments when no operator can intervene.

Typical Areas of Application

Collision monitoring is suitable for almost any machine tool.

Machining centers benefit in particular, as complex geometries and automatic tool changes always pose a risk. If the tool hits the fixture or workpiece, the sensor signal immediately stops the feed.
Lathes often operate at high speeds and with large workpieces. Errors in clamping or programming can trigger serious collisions. Monitoring reacts immediately.
Grinding machines have minimal distances between the grinding wheel and workpiece. Even small mispositions lead to damage. Collision monitoring reliably secures this sensitive process.
Automated manufacturing cells often run unmanned. An incorrectly gripped workpiece or a twisted clamping device can immediately lead to a crash. Monitoring reacts precisely at the moments when no one can intervene.
Special machines and older systems can also be retrofitted. Due to the independent mode of operation, the systems are flexible and provide immediate protection.

Why Montronix is the Right Partner

Experience and Know-how

Montronix has been protecting machine tools for more than 30 years. This experience is reflected in mature solutions that are used worldwide.

Independence from Control System

Our systems work independently of the manufacturer and year of the machine. This means maximum flexibility and safety.

Own Development and Production

Montronix develops and manufactures its products in Germany. This enables short distances, quick adjustments, and consistently high quality.

Test Setups

Many companies want to see for themselves before investing. Montronix offers the opportunity to test systems directly in their own machine.

Expandability

The systems are modular. Those who start with pure collision protection today can later add wear detection, process monitoring, or predictive maintenance.

Support and Training

Montronix supports customers even after installation. Training ensures that employees can use the systems optimally. Support is always available.

Contact

Would you like to reliably protect your machine tools from collisions? Or are you planning automation where maximum safety is crucial?