Maximizing Machine and Tool Lifetime: A Closer Look at Our Collision Monitoring Solution

Improving maintenance and operational practices reduces costs and increases returns for both machine users and builders. Collisions in machine tools are a critical aspect of the machining process, and by precisely monitoring them, you can take proactive actions to extend the lifespan of machine components, boost machine productivity, minimize unexpected downtime, and improve product quality. Learn more about how our Collision Monitoring solution and techniques can help you monitor and track collisions, maximize machine performance, achieve greater efficiency, and save on maintenance and repair costs.

The importance of collision monitoring

Collisions in CNC machines can occur for a variety of reasons; effectively monitoring and tracking them can help in understanding these causes, which is essential for preventing them. Some of the causes of these collisions are work piece material and set-up errors, tool length and diameter mismatches, machine mechanical issues, contact with other machine components, programming errors, and tool wear or breakage.

These collisions can have a significant impact on overall efficiency, machine life-cycle, and product quality. It can also cause structural damage to the CNC machine in the long run, affecting the machine’s integrity, precision, and functionality. Even if a collision does not result in immediate, visible damage, it can have an impact on the machining process’s accuracy. Furthermore, machine repair, emergency stops, and replacing damaged tools or workpieces all result in downtime and production losses, making it critical to understand the causes of collisions and work toward prevention.

IPercept’s solution for collision monitoring

This is where we can help! Years of dedicated research have fueled our advanced automated data analysis designed specifically for the manufacturing industry. We use our domain knowledge and extensive experience to precisely pinpoint collisions in CNC machines and compare their frequency and severity. Then, we fine-tune our smart machine learning algorithms to not only detect but also map these collisions over time in relation to the process, material, and product being machined. This enables operators, production, and maintenance teams to address these issues and prevent further machine damage, thereby increasing productivity and product quality.

In our Predictive Maintenance solutions, we use discrete monitoring, while our collision monitoring solution utilizes continuous monitoring. This system precisely identifies collisions in CNC machines, compares their frequency and severity, and establishes thresholds, alarms, and alerts. What sets it apart is not only the granularity and precision of the results, but also the ability to run this on the edge, simplifying cybersecurity. These insights have enabled us to extend tool life, prevent tool breakage, and take measures to avoid collisions, potentially improving product quality.


Visualizing Data Insights: These plot examples show the visualization of collisions in a CNC machine over time, comparing their frequency and severity.


Our collision monitoring solution shares the same system with our axis and spindle monitoring solutions, offering a significant advantage as these solutions complement each other. For instance, the collisions detected can be further analyzed through tests for axis or spindle monitoring.

This is achieved by retrofitting the machine with our machine-configured Smart IIoT Device, which is equipped with micrometer-accurate vibration and motion sensors and data acquisition system. There is no connection with machine controllers, and this means that cybersecurity is a significant benefit of the service. The device also does not require any connection to the IT infrastructure, and Wi-Fi.


Here’s a look at IPercept’s system architecture and a brief overview of how the system works.


It is truly plug-and-play, with installation and set-up times as short as an hour. Our advanced and patented algorithms then analyze and monitor collisions. This allows for more meaningful insights into maintenance and operations. These insights, along with other notifications, alerts, or alarms, can be viewed directly on our dashboard and additional discussions and deeper insights are shared through presentations and meetings.


“These services are essential for us to restart cost effective production in Europe.” 

– Senior Production Manager, Automotive Manufacturing Company


Follow us on LinkedIn and visit our website for similar content and updates. Click here to get in touch with us if you have any specific questions.