CNC machine
CNC machine monitoring with IoT delivers machine status, part counts and fault states straight to the MES. Operators connect old and new machines through a single standard, without redesigning systems and without lengthy downtime.
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Integrate CNC data via OPC UA without system redesign
Interface connection for CNC machines in live operation
Efficient energy management with intelligent compressed air sensors
CNC machine monitoring: connect old and new machines to the MES
In the solution examples, OPC UA is the common interface. Legacy machines without a data interface receive IoT boxes that pick up digital signals from terminal strips and signal transmitters. FabEagle®Connect from Kontron AIS reads them via Modbus and uses state mapping to generate machine data, part counters and fault states. Newer machines with their own OPC UA interface are integrated directly, and a single OPC UA server provides everything to the MES. On a Liebherr machine with a Siemens 840D control, Prosys OPC UA Forge reads the OPC UA server and outputs the data in XML format. The iguXMLsync software processes it further, for example for MES, Azure or Power BI dashboards. In addition, SICK's FTMg flow sensor collects compressed air data on CNC machines at one customer.
All examples come from mechanical and plant engineering. Gebr. Becker uses FabEagle®Connect to connect more than 40 CNC machines at two sites to MPDV's Hydra MES. The resulting transparency helps optimise production processes and increase machine utilisation. Finnish provider i-GuSystem connected a new Liebherr CNC machine for an international machine builder: it took two hours until the data was flowing in the required format. In podcast episode #94, Stefan Hoppe, managing director of the OPC Foundation, explains how OPC UA connects legacy and new equipment.
Podcast episodes featuring CNC machine
CNC machine monitoring: frequently asked questions
How can legacy CNC machines without an interface be connected to an MES?
Legacy CNC machines without a data interface are connected via IoT boxes that pick up digital signals from existing terminal strips and signal transmitters. At Gebr. Becker, FabEagle®Connect reads these signals via Modbus and turns them into machine data, part counts and fault states. A single OPC UA server provides them to MPDV's Hydra MES. This connects all existing machines through one interface standard, regardless of manufacturer and generation.
How can data be read from a CNC machine?
Data can be read directly from the control of a CNC machine, without additional sensors. i-GuSystem uses the machine's existing interfaces for this, and on newer equipment the OPC UA server. On a Liebherr machine with a Siemens 840D control, Prosys OPC UA Forge reads the data and passes it in XML format to the existing iguXMLsync software. It took two hours until the data was flowing.
How does connecting CNC machines increase machine utilisation?
Connected CNC machines continuously report machine status, part counts and fault states to the MES, which monitors and visualises the data. At Gebr. Becker, more than 40 CNC machines at two sites deliver their data via FabEagle®Connect to the Hydra MES. The resulting transparency makes it possible to optimise production processes and increase machine utilisation. Older machines without a data interface are included as well.
What does a DNC system do in CNC production?
A DNC system transfers CNC programs to the machines on the shop floor. i-GuSystem combines this program transfer with the collection of machine status and production data and with data management. Its iguXMLsync software prepares the data and transfers it to databases and other systems such as VisualFactory, MES, MQTT-based cloud services or Power BI dashboards. Machines are connected from old RS232 interfaces right up to modern high-end controls.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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