Machine tool
Smart machine tools continuously deliver condition, process and consumption data via IoT. Operators detect faults and deviations earlier, even during unattended weekend shifts, and improve availability and quality.
Machine tool at a glance
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Verified projects featuring Machine tool
Consolidating project costs and machine data on one central data platform
GROB-WERKE and b.telligent consolidate project costs, forecasts and machine data in Microsoft Fabric. Reports now take seconds instead of manual work.
Reducing energy costs through targeted compressed air monitoring
How to safeguard your processes with digital data acquisition
Condition monitoring of machine tools with retrofit sensors
Data-driven optimisation and seamless monitoring of milling processes
Partnership on the shop floor for outsourced services in robotics
Smart machine tools: condition, faults and consumption in view
In the solution examples, older machines without built-in sensors are retrofitted with sensors for vibration, temperature and humidity. With the DATAEAGLE system from Schildknecht AG, the values travel via Bluetooth Low Energy to a gateway that reports critical values to the control and forwards the data via Modbus TCP, Profinet or, if needed, the cellular network. Siemens uses Industrial Edge for Machine Tools to read currents and set and actual position values directly from the control, on an industrial PC in the control cabinet and via the umati interface. ifm measures the machine's consumption with compressed air meters at the supply point and passes the data via IO-Link to the moneo platform, which forwards it via MQTT or OPC UA to AWS or Azure.
The examples come from automotive, mechanical and plant engineering, and metal and electronics, mostly as condition monitoring, quality control or energy monitoring. An automotive parts manufacturer in Portugal monitors its machine tools with DATAEAGLE, which helps it meet delivery dates. GROB-WERKE use GROB4Line to alert on-call staff via an app when a machine reports a fault at the weekend. At JUMO, an AI solution from Device Insight sets up the laser processes in machine tools, and the share of sensors in the highest quality class rose by 20 percent.
Podcast episodes featuring Machine tool
Data Foundation for AI-Driven Production in Mid-Sized Manufacturing
Implementing IoT Successfully: Use Cases, Impact, Partnerships
Operational excellence with real-time dashboard
- Controller in the cloud – future or reality? | #HM22 Special
- Making huge amounts of data manageable for seamless monitoring in CNC production
- High Speed Manufacturing for Metal Processing
- Shopfloor networking strategy: Schaeffler Group creates messaging infrastructure with Schaeffler Digital Solutions
- Warning and escalation concepts for minimizing downtime of coffee vending machines | AI-supported optimization of production processes
- Real-time data from machine tools and cutting tools – digital twin of the machining cycle and machine learning
Smart machine tools: frequently asked questions
How do smart machine tools collect and use machine data?
A smart machine tool reads values from the control or from additional sensors and transmits them to a platform. There, states, faults and consumption are visualised, and limit values trigger alarms. With Industrial Edge for Machine Tools, Siemens merely requests the data from the control, so the process on the machine remains untouched. On older machines without an interface, retrofitted sensors supply the values, for example for vibration and temperature.
Can older machine tools be retrofitted for IoT?
Older machine tools can be retrofitted with sensors, even while production continues. An automotive parts manufacturer in Portugal fitted every machine tool in a block of twelve with four sensors that send their data via a sensor hub and Bluetooth Low Energy to the DATAEAGLE gateway. Because the floor in machining is often oily, wireless was chosen instead of additional Ethernet cabling. The gateway detects critical values and reports them to the control system.
What role does umati play in connecting machine tools?
umati is a uniform communication interface that allows a platform to access the data of every machine tool in a machine park. New machines often speak umati straight from the factory, while older ones supply no data at all. Siemens solves this with Industrial Edge for Machine Tools: the platform runs on an industrial PC in the control cabinet, uses the interface to the control and executes the umati function itself, effectively acting as a converter.
How does machine connectivity prevent downtime during unattended shifts?
Downtime during unattended operation can be avoided if the machine reports faults itself. At GROB, the GROB4Line software module connects the machine by cable or radio to a cloud platform. The app shows status and condition and sends alerts by push notification or email to on-call staff. Overheated gearboxes, worn tools or jammed material are therefore noticed in time, even at the weekend.
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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