New telemetric measurement system with wireless signal transmission for process monitoring

Traditional hard-wired measurement systems quickly reach their limits when machine parts are in motion or difficult to access. It is not wear and tear, but rather the risk of cable breakage that poses the greatest challenges – especially for components subject to dynamic loads. In addition, cables often disrupt operation and restrict flexibility and mobility of sensor systems. Coolants, chips, and dust can cause connectors to malfunction. Batteries, in turn, require regular maintenance or replacement. As a result, critical processes often remain unmonitored, posing high risks of wear, scrap, and process instability.

This is exactly where the new Telemetric Measurement System (TMS) from Kistler sets new standards. It transmits signals wirelessly, continuously, and accurately around the clock. The TMS was specifically developed for single-channel piezoelectric measurements in moving machine elements, such as turret lathes, multi-spindle machines, robots, or assembly lines. Compared to indirect methods, such as spindle current analysis, the TMS – in combination with the highly sensitive piezoelectric sensor – offers significantly higher measurement sensitivity. For the first time, even the slightest forces in the range of a few newtons can be detected directly and with maximum process proximity in industrial manufacturing. It even delivers consistent measurement data in demanding settings such as machine rooms or industrial facilities. This makes the TMS a dependable, cost-efficient alternative where conventional technologies fail.

”Existing wireless solutions on the market are primarily designed for research and development environments. They only have a limited measuring capability and rely on specially configured systems,” explains Kevin Meier, Product Manager Cooperation Solutions in Advanced Manufacturing at Kistler. ”They are often too large or specially designed, making permanent integration into 24/7 production equipment only possible to a limited extent.”

System architecture: two components – one closed system for process monitoring

Telemetric Measurement System for wireless near-field transmission consists of two functionally distinct modules that are mechanically and electrically matched to each other. The miniaturized, single-channel charge amplifier unit type 5190A is mounted directly on moving machine elements, such as the tool turret. It converts the sensor’s raw piezoelectric signal into a voltage signal and transmits it digitally to the base unit type 5290A via the wireless interface. The base unit is firmly mounted on the machine and inductively supplies the amplifier with power. It receives measurement data via the telemetry near-field interface, providing a stable wireless connection even for complex strokes. The gap between the modules is 1 ± 0.5 mm.

Signals are processed with a resolution ranging from ±48 to ±140,000 pC at an analog voltage output of ±10 V. Alternatively, digital data can be output via Ethernet at a sampling rate of up to 25 kSps, including configuration and control through the integrated web UI. Standard interfaces, such as Ethernet, enable straightforward integration into existing control systems or higher-level monitoring platforms, such as the data analysis software PTS App or the process monitoring system maXYmos from Kistler. This allows for tool wear (for example in metal cutting), material deviations, or irregularities in chip formation to be detected in real time.

A robust and maintenance-free telemetric measurement system for continuous operation in manufacturing

Intelligent self-configuration is a key feature of the system. Following an initial setup and coupling via the near-field interface, the base unit automatically identifies the sensor and reads all relevant parameters, including calibration data, measuring range, and sensitivity within milliseconds. This system is immediately ready for measurement – without manual intervention or waiting times. Installation is also fast, precise, and reproducible thanks to defined coupling points. Users experience no delays in the process and no impact on cycle times.

The contactless, high-frequency signal transmission is bidirectional and resistant to interference, even under harsh conditions. The measurement system is highly resistant to chips, coolants, and vibrations thanks to its closed aluminum die-cast housing and ceramic-reinforced transmission surfaces.