CNC machine monitoring that works on every brand and every age of machine

A SenseAi or SenseAi Embedded on each machine, mounted magnetically near the spindle, the tool changer or the motor, on 2.4 GHz Wi-Fi or the IoTFlows 4G/LTE router. From it: each machine’s live running and stopped state on the Assets page; uptime per shift against a goal; part counts and cycle times with Discrete Analysis, for every part the machine runs; downtime with reasons such as Setup / Changeover, Tool Change and Tool Breakage, ranked on a Pareto chart; machine health and shock events that alert people and open work orders in Maintain; Operator View at the machine and wallboards on a TV. On Enterprise, the IoTFlows edge device adds data from the CNC control over MTConnect, OPC UA and other protocols.

Yes. The sensor reads the machine’s vibration from the outside, so it works the same on a Haas, a Mazak, an Okuma, a DMG Mori or any other machine, and on manual machines with no control at all. Every machine reports uptime, stops and parts on the same scale.

Yes. SenseAi needs no connection to the machine: it attaches magnetically in seconds and calibrates in under five minutes, and connects over 2.4 GHz Wi-Fi or the IoTFlows 4G/LTE router, which keeps it off the plant network. A machine from the 1980s reports the same numbers as a new one.

With Discrete Analysis. The sensor sees each cutting burst and the fall back to idle when the operator loads, inspects or changes a tool, and counts one part when the cut ends, so cycle times can change from part to part. Assign every part the machine runs at once; each part’s count and cycle times are reported separately. Validate the set-up against ten parts counted by hand.

It is measured, not reported. The sensor decides running or stopped every second against a threshold set during calibration on 5 to 10 real machining cycles, and you confirm the mount by running the machine cutting, then idle, and checking that the two read differently. A short-stop cutoff keeps measuring and chip clearing out of the downtime list.

Every stop the sensor detects lands on the downtime record. Operators classify it at the machine or on a phone, for example Setup / Changeover, Tool Change or Tool Breakage, and routine stops can classify themselves with automatic rules. After two to four weeks the Pareto chart on the Downtimes report shows what setup costs on each machine, and the same chart shows whether a fix worked.

It depends on how much of the cycle an operator carries: 40 to 60% on a manual, operator-intensive machine, 50 to 70% when an operator loads and unloads, 75 to 85% fully automatic, and 85 to 90% for a lights-out cell. Set each machine’s goal from its own baseline plus 5 to 10%; a goal the machine has never met teaches operators to ignore the number.

Yes, on Enterprise. The IoTFlows edge device reads the control over MTConnect, OPC UA and other protocols, and IoTFlows writes the driver when one is missing. Program, part count, alarms and process values sit beside the sensor’s data and feed the same event rules, so a control alarm can alert people and open a work order. A custom integration typically takes one week to a month and is priced by scope.

SenseAi is $149 and SenseAi Embedded $199 per machine, bought once. The Pro plan is $119 per device per month billed monthly, less on annual and three-year contracts and from 10 devices, and 50 or more devices are quoted. Controller data through the edge device is part of Enterprise, priced by project. A pilot puts IoTFlows on 10 to 25 machines for four weeks with no commitment to buy.