Case Study

CNC Tool (Insert) Condition Monitor

Challenge

A production line was experiencing component rejections at the End of Line (EOL) due to worn CNC cutting inserts that were difficult to identify before machining quality was affected.

PROLABS Solution

PROLABS developed a portable, sensor-based monitoring system using LabVIEW that continuously tracks CNC tool condition in real time. The system automatically detects insert wear and alerts the machine operator when a tool replacement is required. The solution can be easily integrated with virtually any CNC machine.

Results

• Real-time automatic detection of tool insert wear

• Significant reduction in rejected components at the EOL

• Lower production costs by preventing defective machining

• Reduced machine downtime and tool-related failures

• Improved product quality and process reliability

• Portable solution compatible with multiple CNC machines

• Traceability and Industry 4.0