Real-time monitoring and process control secure production processes

Every machining company is aware of the dangers caused by machine collisions, program errors, incorrectly clamped components or defective tools, which lead to production interruptions, longer downtimes and high follow-up costs. The aim was therefore to improve machine protection and the machining process, while also enabling predictive maintenance. They found what they were looking for at Montronix: «The Montronix systems can detect and prevent process-related and technical faults at an early stage, so that unwanted downtimes occur much less frequently today,» explains Peter Rampf, maintenance expert at Everllence. As with any production company, quality assurance, machine utilization and production efficiency play a central role in Everllence's operational processes. Production interruptions not only mean a loss of time and quality, but also considerable costs.

Flexible process monitoring with millisecond response time for safe and stable production

Montronix was able to impress with its flexibility, short response times and simple system integration, regardless of the machine controller and manufacturer. «Our systems have a modular design, can be retrofitted in new and existing systems and have real multiple benefits thanks to the learning mode and automatic calibration,» explains Timo Berndt, Product Manager at Montronix. The Pulse Plus system uses highly sensitive acceleration sensors with integrated temperature measurement to detect vibrations and shocks. A possible collision is detected by the acceleration data as a sum signal from all three sensor axes and if the limit value is exceeded in less than one millisecond, a signal is sent to the fast input of the machine control system, which immediately triggers an emergency stop. However, if the movement before and during a collision is very slow, the Montronix Strainlink sensor is used. Strain gauges measure the forces occurring directly on the machine and thus also cover «blind spots» within the acceleration measurement. «In the past, in the worst case scenario, non-detection meant that the machine geometry had to be checked and readjusted. Today, we change the cutting edge within a very short time and continue production immediately,» says Peter Rampf. In addition to primary immediate protection, continuous data acquisition also enables early detection of creeping wear problems and is therefore also an important component for predictive or preventive maintenance and a stable production process. All axes as well as main and motor spindles are monitored. In addition to machine protection, the Montronix IBU Plus NX evaluation unit also offers condition monitoring with continuous raw data acquisition, open API interfaces and real-time data for external analyses. In addition, the Montronix evaluation unit stores the last 4000 messages and alarms in a ring buffer. If this is not enough, it can be easily expanded with the ServiceAgent option. In this case, all messages and alarms are stored on the customer's own server and can also be sent automatically by e-mail to predefined recipients.

Real-time data acquisition and bidirectional communication for adaptive maintenance and AI-supported process optimization

Everllence goes one step further and streams the vibration and force data continuously supplied by the sensors directly from the Montronix evaluation unit to the Everllence digital production platform via API, OPC UA and MQTT. There, it is linked with other machine data such as power consumption, axis movements and running times. The data from the machines and the Montronix sensors is stored and evaluated by Everllence in a cloud with the aim of enabling AI-supported analysis for predictive maintenance. The open Montronix API allows limit values and filter parameters to be adjusted directly by external systems. «Everything that the operator can set can also be set by higher-level software,» explains Timo Berndt. This creates bidirectional communication between the individual monitoring systems and the higher-level production IT, which then forms the basis for further process optimization, machine utilization, adaptive maintenance intervals and future AI applications. A customized dashboard visualizes all important parameters, key figures and status messages in real time, providing a comprehensive overview for data analysis and monitoring.

In addition to fixed systems, Everllence also uses the Montronix WiFi Box Plus. This mobile system contains the same sensor as the stationary devices, but transmits the data wirelessly to a mobile computer. This also enables short-term, mobile analysis of machines without a built-in monitoring unit. Examples of the benefits of preventive mobile measurements are clear to see: detection of a loose or worn bearing assembly on the spindle or the diagnosis of grinding spindle problems, as well as the targeted reduction of vibrations on a wire erosion system have already led to significant cost savings at Everllence.

Higher availability, predictable maintenance and measurable efficiency gains

Over the past few years of using Montronix process monitoring systems, Everllence has seen clear benefits. The data is not only used to diagnose faults, but also to improve machining strategies, for example by adjusting feed or milling parameters. In combination with the open interface architecture, this creates a system that not only protects, but also actively contributes to process optimization - and thus sustainably strengthens the competitiveness of production. In practice, unplanned downtimes have been significantly reduced, wear has been detected at an early stage and preventive maintenance measures have been planned as a result. Apart from this, protecting the expensive spindles has already saved a lot of money. A small example from 2023 makes it clear that it was the Montronix system that prevented a small tool breakage from causing major damage. Back then, the tip of a drill broke off in the connecting rod production department at Everllence. As this was a blind hole, it could not be detected by the operator. The Montronix strain gauge and acceleration sensor detected the incident immediately, stopped the system and prevented damage.

Manufacturer-independent modular monitoring systems for safe production and future AI-supported process control

Montronix systems are manufacturer-independent and can be integrated into machines with Siemens, Heidenhain, Fanuc, Mitsubishi or other control systems. «Our systems can be integrated into any machine, regardless of the control system, whether new or as a retrofit,» emphasizes Mr. Berndt. At Everllence, we plan to use them in new lines for turbocharger and cylinder housing production. The combination of modular hardware, open API interface architecture and tried-and-tested, adaptive algorithms makes the Montronix devices a future-proof investment. This means that production is not only protected against sudden crashes, but is also technologically prepared for future developments in condition monitoring, predictive maintenance and AI-supported process control.

About Montronix and Everllence

The Montronix GmbH was founded in 1990 as a spin-off of Kennametal and quickly established itself as a reliable supplier of process and tool monitoring systems. Growth Finance AG has been supporting the company's international expansion since 2001. Based in Murr and with over 20,000 systems installed, Montronix is one of the leading providers in the industry. The portfolio includes solutions for process monitoring, machine protection and diagnostics - for greater efficiency, quality and flexibility in production, particularly in the automotive and aerospace industries.

Everllence (formerly: MAN Energy Solutions) is a leading provider of propulsion, decarbonization and efficiency solutions for shipping, the energy sector and industry. True to the motto „Moving Big Things to Zero“, the company supports key global industries in reducing emissions that are difficult to avoid. Its technologies have a measurable impact on the success of the global energy transition. Everllence is headquartered in Germany and employs around 15,000 people at more than 140 locations worldwide. Customers also benefit from the global service center network of the after-sales brand, Everllence PrimeServ.

More information at: www.montronix.com and www.everllence.com