n TECHNOLOGY October 2025 www.drivesncontrols.com 18 THE SWISS MEASUREMENT SPECIALIST Kistler has announced a system that provides wear-free, wireless transmission of signals to monitor processes and equipment in dynamic structures such as machine tools. The Telemetric Measurement System (TMS) system delivers data reliably without needing sliprings, batteries or cables. Kistler says it opens up entirely new possibilities for process monitoring in series production. Traditional hard-wired measurement systems reach their limits when machine parts are moving or difficult to access. It is not wear-andtear, but the risk of cable breakage that poses the biggest challenges – especially for components subject to dynamic loads. In addition, cables can disrupt operation and restrict the flexibility and movement of sensor systems. Coolants, chips and dust can cause connectors to malfunction. If batteries are used, they need regular maintenance and/or replacement. As a result, critical processes often go unmonitored, posing risks of wear, wastage and process instability. Kistler’s TMS transmits signals wirelessly, accurately and continuously. It was developed primarily for use with single-channel piezoelectric measurement devices in moving machines such as turret lathes, multi-spindle machines, robots and assembly lines. Compared to indirect methods, such as spindle current analysis, the TMS – in combination with the piezoelectric sensors – offers much higher sensitivities. Even tiny forces of a few newtons can be detected directly, “for the first time” according to Kistler. The system is claimed to deliver consistent measurement data in demanding locations such as machine rooms or industrial facilities, making it a cost-effective, reliable alternative where conventional technologies fail. “Existing wireless solutions are primarily designed for R&D environments,” explains Kevin Meier, Kistler’s product manager for cooperation solutions in advanced manufacturing. “They only have a limited measuring capability and rely on specially configured systems. They are often too large or specially designed, making permanent integration into 24/7 production equipment only possible to a limited extent.” Kistler’s Telemetric Measurement System consists of two modules that are matched mechanically and electrically. One is a miniature, single-channel charge amplifier that is mounted directly onto moving machine elements, such as tool turrets. It converts a sensor’s piezoelectric signal into a voltage and transmits it wirelessly to a base station mounted on the machine, which powers the amplifier inductively. The base unit receives measurement data via a near-field interface, providing a stable connection even when complex movements are involved. The gap between the modules is 1mm (±0.5). The signals are processed with a resolution from ±48 to ±140,000pC (picoCoulombs) at an analogue voltage output of ±10V. Alternatively, digital data can be output via Ethernet at a sampling rate of up to 25 kilosamples/s, via a Web UI. Ethernet interfaces allow integration into control systems or higher-level monitoring platforms. Tool wear (in metal-cutting, for example), material deviations, or irregularities in chip formation, can be detected in real time. Following an initial set-up and coupling via the near-field interface, the base station identifies the sensor automatically and reads all relevant parameters, including calibration data, measuring range and sensitivity, within milliseconds. The system is immediately ready for measurement – without manual intervention or waiting times. Installation is said to be fast, precise and reproducible, thanks to defined coupling points. The contactless, high-frequency signal transmission is bidirectional and resists interference, even under harsh conditions. The measurement system also resists chips, coolants, and vibrations because of its closed aluminium die-cast housing and ceramic-reinforced transmission surfaces. www.kistler.com/GB/en p Following the transfer of the FDT/DTM assets to FieldComm Group in 2024, the organisation has accelerated its efforts to unify device integration. It has announced a timeline for releasing an updated Field Device Integration (FDI) specification, marking a critical step towards unifying integration across the process, hybrid and factory automation sectors. With contributions from OPC Foundation, ODVA and PI, a committee is harmonising the FDI and FDT technologies, with the aim of delivering a unified, scalable integration standard that addresses the needs of modern manufacturing. The updated FDI Specification is due for release by the end of 2026, with the first FDI-enabled systems and devices expected to reach the market in 2029. p Siemens has formed a partnership with machine tools and laser manufacturer Trumpf aimed at elevating industrial production by harnessing advanced digital manufacturing technologies. The collaboration combines Siemens' Xcelerator portfolio with Trumpf's machine-building and software expertise. The partnership will address a key challenge in manufacturing: the gap between IT (information technology) and OT (operational technology) systems, that has historically hindered production efficiency and innovation. By combining the Xcelerator portfolio with Trumpf’s manufacturing know-how, the two aim to deliver technologies that bridge the gap. They are working on open, interoperable IT interfaces that advance AI readiness for motion control applications. p ABB has introduced software that allows real-time coordination of production planning and operations across entire paper mills, aimed at improving their quality, efficiency and profitability by enabling end-to-end traceability, dynamic optimisation and smarter decision-making. The ABB Ability Plant Optimizer for Pulp Mills will help pulp producers to bridge the gap between production planning and realtime operations. p The US robotic tooling and automation specialist, IPR Robotics, has launched a customisable dual seventh-axis system that extends robot reaches, enhancing flexibility and reducing complexity. The StackTrax system can extend a robot’s working envelope, while saving space and deployment time compared to overhead or gantry-style systems. It combines two linear axes in a compact system that gives robots the working envelope of a gantry without the overhead supports, long lead times, or costly custom engineering. It works with all major robots, and can handle a wide range of payloads. The system has been designed to meet the needs of CNC, material removal, and other machine-tending robotic applications www.iprrobotics.com TECHNOLOGY BRIEFS Wear-free wireless system ‘revolutionises’ monitoring of moving machinery Kistler’s Telemetric Measurement System installed on a machine tool. The system consists of a mobile charge amplifier (below left) and a stationary base station (below right).
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