Now it can get rolling ... Telemetry-Based Kistler Measuring System Reads Data Directly in the Lathe

Related Vendors

FAULHABER Drive Systems

SIMTOS (Seoul International Machine Tool Show)

With the new Telemetric Measuring System (TMS) from Kistler, wireless and wear-free signal transmission for process and tool monitoring has been achieved for the first time ...

In modern, highly dynamic industrial production environments, automated processes dominate. However, especially where components rotate or move linearly, traditional wired measurement technology reaches its physical and economic limits. Whether it's turret lathes for automated tool changes, tightly synchronized rotary table assembly systems, or automated robotic grippers, moving and indexing machine or production line systems are virtually omnipresent in industrial manufacturing. This is precisely where traditional sensor technology reaches its boundaries. While stationary measurement setups are well established in production machinery, moving components often remain a "black box." Indirect measurements, such as monitoring spindle current or drive power, provide some clues but are not sufficiently sensitive, particularly with low forces. And when very small forces, strains, or specific acceleration values determine quality, indirect monitoring does not deliver a usable signal. As a result, this data is missing for real-time quality verification, for early detection of deviations, to optimize cycle times, and to plan maintenance proactively—all of which are well-known core requirements of modern production systems.

Measuring at the Site of Machine Operations is Not Trivial

And often, only measurements close to the point of application provide meaningful values. However, physical cable routing has so far made such installations nearly impossible in practice. On indexing or linearly moving axes, continuous cabling is also the weakest point, as mechanical stress, constant movement, and tight bending radii lead to rapid material fatigue. Slip rings wear out due to friction, and cables can break. While battery-powered sensors solve the issue of physical cables, they require significant maintenance and are often impractical in highly synchronized 24/7 productions—failing to ensure either wear-free connectivity or maintenance-free continuous operation. Highly sensitive piezoelectric (PE) sensors for force, pressure, or strain provide meaningful and highly dynamic measurement results. However, to guarantee the highest resolution of even the smallest process forces in the Newton range, these sensors must be as close to the process as possible—ideally directly on moving machine components, such as tool holders or grippers. This is where the technological challenge begins! How, for instance, is the charge amplifier of a PE sensor reliably powered? And how are its high-resolution signals transferred interference-free to the control system?

A Two-Part System Pushes Aside Previous Limitations

This critical hurdle in measuring on moving machine components is overcome by Kistler's telemetric measurement system (TMS). It is based on a two-part system that decouples power supply and data transmission. On one hand, it consists of a mobile charge amplifier module, and on the other, a stationary base module for signal conditioning. The mobile charge amplifier module 5190A is mounted directly on the moving machine component and connected directly to the piezoelectric sensor. PE sensors generate only very small electrical charges in the picocoulomb range. The 5190A converts this signal on-site into a robust, low-impedance voltage signal, digitizes it, and thus ensures high signal integrity, even under harsh conditions. With protection class IP67, the module is also designed for demanding industrial environments. Its compact design allows flexible mounting as well as quick sensor and tool changes—without interrupting the production process.