Tool Condition Monitoring (TCM)

Real-time insight into tool condition and machining process stability

Tool condition monitoring (TCM) uses PnP vibration and current sensors to monitor machining operations in real-time. This data enables early detection of tool wear and abnormal cutting behaviour, allowing manufacturers to intervene before failure occurs. By preventing unexpected tool breakage, you reduce scrap and avoid unplanned machine downtime.

The continuous flow of reliable process data improves overall process stability and ensures consistent part quality. Manufacturers can extend tool life, optimise cutting parameters and make more informed decisions based on actual machining data rather than assumptions.

This solution is part of a new generation of cutting tool technologies designed to accelerate digitalization, innovation, and productivity in machining operations.

The old way

Traditionally, machining operations relied on manual data collection and delayed analysis. During production, operators recorded cycle times, downtime, part counts and quality checks using whiteboards or spreadsheets. This process often resulted in duplicate entries and limited visibility into what was happening during machining. Meanwhile, energy consumption and process inefficiencies remained largely hidden

The new way | PnP solutions

With PnP Sensors, machining operations move from delayed reporting to real-time monitoring. Plug-and-play vibration and current sensors capture machining data directly from the machine during cutting operations. This data is processed in real time and visualised through automated charts and reports, giving you clear insight.

Sensors capture vibration and current signals
Data is transmitted to the monitoring platform
Software generates data charts and reports
Operators detect tool wear and machining instability

The sensor is designed for pracitcal use offering a low cost, portable, and wireless solution with easy setup and a user-friendly interface.

Real Industrial Case Study

Mazak Integrex i-200ST

Material: 316L stainless steel

Operation: Facing

Cutting parameters
Vc: 200 m/min
ap: 1 mm
fn: 0.25 mm/rev

Insterts: CNMG 120408 - PHH920

Observation: Spindle motor current increases progressively with tool wear

Result: The system detected tool wear early on, preventing tool failure and stabilising the machining process

Advantages

Real-time process monitoring
Cutting tool testing and validation
Early detection of tool wear or breakage
Quick diagnosis of the cutting process
Data-driven optimisation of cutting parameters

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