DE 
EN 
IT Machine Diagnostics: Our System for Fast Error Detection
Our machine diagnostics detect deviations in the process in real time and protect your production from downtime. Sensors and evaluation units provide precise data, analyze causes, and immediately report critical conditions. You intervene in a targeted manner before damage or scrap parts occur.
Learn more now
Challenges in Machine Diagnostics
Fractions of a second decide whether a vibration, a force increase, or a cutting error leads to a machine stop. Without continuous machine diagnostics, the cause often remains hidden until scrap is produced or spindles are damaged.
Different controls, years of manufacture, and machine types often prevent the use of a standardized solution. If experienced personnel are lacking, troubleshooting takes longer and downtimes are significantly extended.
Our Machine Diagnostics Method
Montronix machine diagnostics use an interplay of sensors, signal processing, evaluation, and visualization:
- Sensors: Power sensors and vibration sensors record physical quantities directly at the tool, spindle, or machine structure.
- Signal amplification and filtering: Raw data is processed, interference signals are filtered, and values are adjusted to material parameters.
- Real-time evaluation: Deviations trigger warnings or a machine stop within milliseconds.
- Integration into systems: Machine diagnostics are integrated via Profibus, Profinet, or digital inputs and outputs.
- Visualization and documentation: Process data appears on the HMI or PC, reports and optimizations can be derived.
Typical Causes of Machine Vibrations
Vibrations are caused by mechanical errors, wear, or incorrect assembly and have a direct impact on process and part quality. Those who know the causes can identify problems in a targeted manner and avoid failures.
- Imbalances: uneven mass distribution in rotating parts
- Bearing damage: defective rollers or cages generate characteristic frequencies
- Alignment errors: incorrectly mounted components lead to vibrations
- Tool errors: dull cutting edges or breakages generate irregular signals
- Collisions: sudden impacts directly affect the spindle and machine structure
Core Components of Montronix Machine Diagnostics
Effective machine diagnostics require precise measurements, fast data processing, and reliable integration. The following core components work together to detect and correct faults at an early stage.
These Functions and Processes are Covered by Our System
- Detecting vibrations: Vibration overloads, tool wear, and chatter marks are analyzed.
- Tool breakage: Sudden changes in force or vibration stop the process immediately.
- Tool wear: Gradual wear becomes visible before dimensional deviations occur.
- Missing tools: Incorrect equipment or missing tools are detected.
- Machining behavior: Deviations in feed, cutting force, or resonance indicate instabilities.
- Collisions: Dimensional errors are detected and damage is prevented.
- Process documentation: All data is recorded and used for quality assurance or audits.
Mobile Machine Diagnostics with the WiFi Box Plus
The WiFi Box Plus enables fast and flexible condition monitoring without fixed wiring. Using a Pulse Plus sensor, it records all vibrations of a machine. Ideal for mobile analyses, short-term tests, or changing systems.
- Wireless data transmission: Real-time sensor data is transmitted via WLAN to the DIAG evaluation software.
- Easy placement: Attachment with magnetic feet, ready for use in a few minutes.
- Wide range of applications: Temporary diagnostics, fingerprints, commissioning, or maintenance tests.
The WiFi Box Plus complements stationary systems and offers maximum flexibility for mobile tests on different machines.
Creating Machine Fingerprints
The WiFi Box Plus is often used to create fingerprints. Machine manufacturers document vibration values before delivery, operators use them later for comparison. This allows wear to be detected or a successful repair to be proven.
Advantages of Machine Diagnostics by Montronix
Targeted Use of Tool Life
You use each tool up to its actual wear limit. This reduces costs by up to 30% and lowers setup times.
Consistently Ensure Quality
The system detects changes in machining behavior before tolerances are violated. Quality remains stable, even with changing materials or operators.
Reduce Unplanned Downtime
Early warnings give you time to correct errors before the process stops. This increases production time and reduces idle time.
Make Processes Measurable
With up to 26,667 measured values per axis, you get data for well-founded decisions and targeted optimizations.
Flexible Integration
Machine diagnostics can be integrated independently of control and year of manufacture. Existing systems also benefit immediately.
This is How We Support Your Machine Diagnostics
Our services include an analysis of your machines and processes. We select the optimal combination of sensors, evaluation units, and interfaces, install the system, and test it under real production conditions.
On request, we provide test systems and train your employees. Our support is always available for technical questions.
Contact us nowAreas of Application for Our Solutions
- New machines: Fingerprints of linear or rotary axes as reference values for wear detection or after repairs.
- Grinding machines: Analysis of vibrations to avoid surface defects.
- Machining centers: Diagnosis of wear in axes or analysis of unwanted vibrations.
- Pumps and units: Permanent wear monitoring even in humid or dusty environments.
Start Machine Diagnostics Now
Avoid downtime, ensure your quality, and increase the utilization of your equipment. Request your personal offer or book a test setup. We are happy to visit you for personal advice and let you experience machine diagnostics live in action on your machine.
Send inquiry nowFAQ: Frequently Asked Questions about Machine Diagnostics
Does the built-in machine diagnostics have to be purchased separately?
The standard IBU Plus and Pulse Plus collision protection system already includes automatic machine diagnostics for linear and rotary axes. This means the system automatically detects wear if you regularly move all linear axes over their full length in both directions, or run rotary axes at five different speed levels without load, e.g. every morning when you warm up your machine in idle cycle. If the limit value is exceeded over time, the IBU Plus will notify you, so you know that wear is present. The diagnostic software, on the other hand, is a paid option. With this option, you can see which component is worn – whether it is the ball screw, the guideway, the spindle bearing, or whether an external signal is influencing your machining process, e.g. a nearby press without its own foundation.
Is machine diagnostics also suitable for older machines?
Yes, the systems are completely control-independent and can be integrated into almost any machine. Connection is via digital inputs and outputs or common fieldbus interfaces. This eliminates the need for costly control retrofits. Even older machine parks benefit from real-time monitoring.
Can I test the system before purchase?
Yes, we offer test installations directly in your production. You experience the functionality with your own workpieces and processes. During the test phase, you receive a complete evaluation of the recorded data. After completion, you can continue to use the system seamlessly if it meets your expectations.