Solution · Tool & Process Monitoring
Watch the cut, not the clock.
Spindle current, additional sensors and controller data — evaluated only while the tool is actually in the material, and summed up per cut in values you can follow as a trend, set limits on and, where the data supports it, train a model on.
The problem
What you are up against.
- 01
Tool wear and process changes show up in fast signals that an MES reading a value every 30 seconds never sees.
- 02
Comparing cuts only works if you compare the cuts themselves. Fixed time slots average the time the tool spends in the air into every number.
- 03
A monitoring rule written for one machine rarely carries over to the next without starting again.
The approach
Capture as fast as the process demands
Spindle current and additional sensors are recorded in full detail; load and program data come from the controller. Nothing is averaged away in the archive, and the live chart still shows every peak.
Look at the cut only
Toleron recognises from the machine's own signal or the program status when a pass is running, and from the spindle current when the tool is actually cutting. Both checks run at the machine; if either is unclear, the cut is left out rather than evaluated wrongly. The result is exactly one comparable record per cut — checked on recorded passes, not assumed.
Compare, set limits, decide
The values per cut become ordinary curves: compare them with the previous part, set limits that mark a cut as OK or conspicuous, record a cut automatically when a limit is crossed — or hand them to a tested model that first only observes before anyone trusts its rating.
What we use
- Spindle current, measured with a retrofit sensor
- Additional sensors at the machine, where the process needs them
- Spindle load, speed and program status from the controller
- The machine's own signal marking each pass
What you get
- One comparable record per cut, aligned to the actual cut
- Automatic OK / conspicuous rating, with full recordings of conspicuous cuts
- Trends across parts, shifts and days
- A tested path from these values to a model that observes first
Tested on
- LabA.Haas Multigrind CB — spindle current, additional sensors and the machine's own pass signal
- LabHanwha XD38II — spindle current
- LabZiersch surface grinder — spindle current and additional sensors
Tested on the lab machines in Tuttlingen — proof that it works, not customer references.
Go deeper
Related
Cut Detection
Evaluates only the time the tool is actually cutting — not the minutes in between.
Learn moreRetrofit Sensors
Retrofitted sensors capture what the controller does not report — in full detail, on old and new machines.
Learn moreAnalytics & OEE
Turns machine data into OEE, downtime and your own evaluations — set up once, reused on every machine.
Learn moreNext step
Bring tool & process monitoring to your machines.
We start with one machine and the signals it already has. Tell us the controller and the question, and we will tell you what the first weeks look like.