AiVibeTool Condition Monitoring (TCM)
Tool condition monitoring detects tool wear, breakage and missing tools during or between cuts, using signals such as spindle load, cutting force, vibration and acoustic emission, or direct checks with tool setters and cameras.
Indirect TCM systems compare live process signals with a learned or taught reference for each operation. Spindle power or current, feed-drive load, cutting forces from dynamometers, vibration from accelerometers and acoustic emission all change as a tool wears or breaks. Direct methods check the tool itself, for example with a laser or contact tool setter between operations or with a camera inspecting the edge. Machine learning models are increasingly applied to classify wear states from these signals.
TCM is used to stop the machine quickly when a tool breaks, preventing scrapped parts and damage to following tools, and to replace tools based on condition rather than fixed counts. It is particularly valuable for unattended machining, expensive workpieces and high-volume lines, such as automotive component machining.
Signals depend strongly on material, toolpath and engagement, so reliable monitoring needs per-operation baselines and careful threshold setting to balance missed detections against false alarms. Spindle load data can often be read through controller interfaces such as FANUC FOCAS, OPC UA or MTConnect, while force and acoustic emission need added sensors. TCM complements, but does not replace, sound process design and tool life limits.
Key points
- Detects wear, breakage and missing tools from process signals or direct checks
- Signals include spindle load, force, vibration and acoustic emission
- Stops the machine on breakage and supports condition-based tool changes
- Needs per-operation baselines to avoid missed detections and false alarms
Where AiVibe comes in
AiVibe designs and manufactures the AiAmbA AI Factory: edge devices plus AI agents that let people talk to CNC, PLC and robot controllers in plain language. Agents only propose changes, and a trained operator confirms each one.