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Kistler Telemetry Brings Light Into the Previous "Black Box"

The stationary base module 5290A is permanently installed on a machine component and ensures wireless, wear-free communication with the mobile charge amplifier via near-field telemetry. Once the mobile amplifier module is positioned at a defined spot above the stationary base module, two parallel processes take place: the base module inductively and contactlessly supplies the charge amplifier module with energy. This makes the system completely battery-free, maintenance-free, and explicitly designed for continuous 24/7 operation. At the same time, the mobile module transmits the digitized, high-resolution measurement data stream in real time to the base module, which forwards the process data via standard interfaces (analog output or Ethernet) to higher-level process monitoring systems such as Kistler's "maXYmos" or directly to a machine control or monitoring software. In this way, telemetry transforms the "black box" of moving machine components into a transparent, data-driven foundation for process optimization, quality assurance, and condition monitoring. Precise real-time measurements are now reliably and maintenance-free possible on rotating and linearly moving machine components—even in hard-to-reach locations.

Machining as a Good Example of an Application Field:

In machine tools with turrets or multi-spindle lathes, cutting forces are crucial for process stability and product quality. The two-part TMS allows a single-component piezo sensor to be placed directly in the tool holder or on other moving structures. The sensor can thus be integrated in close proximity to the cutting edge, which was often not possible in series production before. The compact charge amplifier module moves along with the structure. By coupling with the base module through the rotational motion of the tool turret, the charge amplifier module is supplied with power, enabling it to digitize the signal and transmit it wirelessly to the stationary base module. The high-resolution data obtained enables predictive maintenance, such as detecting a gradual increase in cutting force as an indication of tool wear. This allows personnel to perform tool changes in a timely manner before tolerance violations or tool breakage occur. At the same time, the precise force measurements allow targeted process optimization by adjusting feed rate, rotation speed, and cutting parameters to ensure optimal tool utilization. Critical situations, such as sudden force peaks, are detected by the process monitoring system within milliseconds. A machine stop reliably prevents costly consequential damage to the turret, spindle, or workpiece—laying the foundation for further automation, which in the long term also enables operation during ghost shifts. The optimized tool life reduces the number of tool changes, relieves personnel, and minimizes machine downtimes—directly increasing overall equipment effectiveness (OEE).

Joining and Assembling are Additional Application Fields for the TMS

In assembly processes on moving rotary tables, such as pin pressing, riveting, and clinching, the precise control of joining force plays a central role in the quality of the connection. In the TMS, the force sensor and charge amplifier can be placed directly on the mobile workpiece carrier to capture the complete process signature, such as the force-displacement or force-time curve, for each joining stroke. This data is transmitted in real time to the controller, which immediately delivers a "good/bad" evaluation for each part. The system detects faulty joining processes caused by incorrect force or position in real time, enabling 100% inline quality control. Scrap is reduced, defective assemblies do not proceed to subsequent process steps, and overall production quality increases significantly, while manual inspection efforts in the quality department are significantly reduced—with the long-term goal of achieving zero-defect production.

Telemetry is the Key to the Gateway to Industry 4.0

Telemetry creates transparency in previously hard-to-measure, dynamic areas of manufacturing. With increasing networking through the Industrial Internet of Things (IIoT), telemetry systems provide high-frequency data streams that supply AI-supported analyses, digital twins, and adaptive control systems with high-quality input.

Telemetric measurement systems thus become a central element of Industry 4.0. The high-quality data provides the foundation for more precise process control, higher product quality, and improved plant availability. At the same time, they pave the way for future innovations in the smart factory. Process signatures obtained through telemetry enable reactive inline quality control, predictive maintenance, and data-driven decisions that sustainably improve cycle times, process stability, and plant availability.