SIGER Tool Monitoring System

SIGER Tool Monitoring System (TMS) collects over 30 dimensions of data signals, including spindle current (load), and integrates self-learning algorithms with years of industry experience to achieve precise monitoring of tool wear, tool chipping, and tool breakage. It automatically triggers alarms and stops operations to prevent batch defects caused by tool failures. This system effectively extends tool life by over 30%, ensuring higher efficiency and cost savings.

Tool management in precision machining industry: 8 major failure modes and monitoring solutions

Comparison of tool monitoring methods：

Tool monitoring system: embedded system, real-time monitoring (wear/breakage/chipping), remaining life prediction | intelligent shutdown control

 Hardware structure and data flow :                                               Edge collection, edge processing, efficient analysis and interaction!

Abnormal state trend:

In the process of tool machining, according to the change of load, there are five states of tools: normal, slight wear, wear, chipping, and breakage.

Real-time monitoring of machining process: turning processing, milling processing, drilling, tapping, tooth surface machining, curved surface and other machining scenarios

Typical load characteristics in the tool machining process: tool hipping,breakage,chip entanglement,chip accumulation,abnormal clamping,chatter mark

Typical load characteristics in tooling process: Abnormal Wear | Defects like Burrs & Whitening

SCADA system integration                                                             Data export, system integration, and centralized monitoring display!

The system reserved communication interface supports alarm data and characteristic curve export, tool monitoring data summary display, third-party platform docking display.

Application scenarios of tool monitoring system: 

System Compatibility Scope:

Applicable Machine Types: Machining centers, gantry machines, lathes, turn-mill complexes, and other cutting scenarios.

Applicable Processes: Mass repetitive machining, mass nested process machining, small-batch machining, non-NC scenarios, and other process types.

Applicable Machining Methods: Turning | Milling | Drilling | Tapping | Gear surface machining | Contouring, and other roughing/finishing scenarios (minimum cutting depth: 0.1mm).

A Leading Apple Supplier’s Tool Monitoring System: Computer & Electronics Manufacturing, Breakage/Chipping Detection , Tool Life Prediction

Customer Overview: The customer is a domestic manufacturer of  mobile phone, computer and other electronic products and accessories. The production business covers the design, manufacturing and assembly services of electronic products. It is the head supplier of manufacturing accessories for international famous brands.

Effect verification and value output: real-time monitoring of machining status,idle machining, tool wear detection,over-limit alarm & automatic shutdown

On-site Implementation Validation:Focused on customer pain points, the field test validated T1 milling tool breakage and T2 milling tool wear failure.

Validation Results:By comparing time-series curves of normal vs. idle machining, and normal vs. worn tools, the system clearly distinguished failure scenarios (e.g., idle runs and tool wear).

System Value Output: Help customers achieve 100% effective monitoring and shutdown control of the machining process, avoid product loss risks, and effectively reduce tool costs.

Tool Monitoring System for a Tesla Tier-1 Supplier: Automotive Components | Tool Wear Detection | Edge Chipping Identification | Remaining Life Prediction

Customer profile: Main products include precision machined components for automotive transmission systems, drivetrains, and other core systems. As a Tier 1 supplier, they serve internationally renowned automakers such as Tesla, Great Wall, and ZF.

Effect verification and value output: lathe wear monitoring , extreme life prediction, tool change reminder              

On-site Implementation Validation: Focusing on customer pain points in management, the on-site validation primarily involved identifying and verifying tool wear conditions and idle machining states.

Validation Results: Comparative analysis of T1 worn tools versus normal tools' time-series data clearly identifies tool wear conditions. Characteristic value analysis can effectively predict ultimate tool life.

System Value Output: Digitizing and intelligently applying manual experience enables effective tool wear detection; extending tool replacement cycles significantly reduces tool costs.

Construction Equipment Tool Monitoring System:

Customer profile: The company is a large national backbone enterprise established in China, specializing in the production and sales of a series of bulldozers, road construction machinery, and other engineering machinery hosts and their components.

Effect verification and value output: vertical machining center,broken knife monitoring ,wear identification 

On-site Installation and Deployment Verification: Based on customer pain points, conduct real-time verification of drill bit breakage and reamer wear status; 

Verification Results: By comparing the time-series curves of worn tools, normal tools, and empty machining for T4 drills and T5 reamers, empty machining and wear abnormalities can be clearly distinguished;

System Value Output: Through envelope monitoring management, help customers intelligently identify tool abnormalities, reduce product scrap risk, while significantly cutting tool costs.

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Official Contact Info:

Email: marketing@siger-data.com

WhatsApp: +86 189 6235 3927

WaChat:189 6235 3927