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IT Tool Monitoring System from Montronix
With a tool monitoring system from Montronix, you secure your production from the very first workpiece. The sensors detect tool breakage, wear, or process errors in real time and the evaluation reacts within milliseconds.
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Components of Our Tool Monitoring System
A tool monitoring system consists of sensors, signal processing, and evaluation that are precisely matched to each other. The sensors detect deviations in the machining process, the evaluation unit processes the data in real time, and immediately triggers the appropriate reaction.
Sensors
Sensors measure power, vibration, force, and structure-borne sound directly at the tool, spindle, or machine structure. With up to 26,667 measurements per second, they detect even the smallest changes.
Signal Processing
The data passes through amplifiers and filters that are precisely matched to the tool and material. This way, we separate normal process fluctuations from real errors.
Evaluation
The evaluation unit Spectra ONE compares current measurements with reference data. In case of deviations, a stop signal or warning is triggered immediately.
Integration
Via Profibus, Profinet, or digital inputs and outputs, you can integrate the system into any machine. Even older systems can be retrofitted quickly.
Our Solutions at a Glance
Our Service for Your Tool Monitoring System
We support you from analysis to a ready-to-use system:
- Consulting: We review your processes and recommend the right solution.
- Installation: Our team integrates the technology directly into your system.
- Test setup: You test the system in your production under real conditions.
- Training & Support: We train your staff for the application and are always available for questions.
Your Advantages with Tool Monitoring Systems from Montronix
Immediate Error Detection
The system stops the machine within milliseconds in case of tool breakage or collision. This protects spindle and fixtures and reduces costs.
Scrap Control and Quality Assurance
The monitoring immediately detects faulty machining and interrupts the process. This ensures dimensional accuracy and avoids rework.
Tool Life Optimization
The system uses each tool up to the wear limit. This reduces tool costs by an average of 20 to 30% and shortens setup times.
Safety in Unmanned Operation
The sensors automatically monitor the process. Even in night shifts, production remains stable and free of scrap.
Plannable Maintenance
The system documents process data over long periods. On this basis, you can plan maintenance in a targeted manner.
Transparent Processes
All measured values are available digitally. With this data you can adjust cutting strategies and increase machine performance.
Where Our Tool Monitoring Systems are Used
- Machining centers: Monitoring of breakage, wear, collision, and signal deviations.
- Automated production lines: Permanent control in multi-spindle systems or transfer lines.
- Grinding machines: Detection of vibrations to avoid surface defects.
- Robots & handling systems: Control of load peaks and alignment errors.
Contact
Would you like to prevent tool breakage, detect wear in time, and permanently protect machines? Request your personal offer for a tool monitoring system from Montronix now or get direct advice.
Send inquiry nowFAQ: Frequently Asked Questions about the Tool Monitoring System
How fast does the system react?
The sensors reliably detect deviations and immediately send a stop signal to the machine control in case of deviations from the target value. This immediately stops the machining process and prevents further damage. At the same time, you ensure the quality of your components before scrap occurs. The fast reaction is crucial to exclude unplanned downtimes.
Which errors does the system detect?
The tool monitoring system identifies tool breakage, wear, wrong or missing tools, and process anomalies. It also detects collisions or material defects in the machining process. This covers the main causes of scrap and machine damage. The operator receives clear information and can act immediately.
What challenges are there with common tool monitoring systems?
Many systems are highly dependent on a specific CNC control and cannot be retrofitted without adaptation. This leads to high integration costs or limitations in mixed machine parks. In addition, simple systems often react too late or only detect certain types of errors such as tool breakage, but not wear or material deviations. Montronix solves these problems with control-independent interfaces and a combination of several sensor types that cover the entire process.