THK Monitoring AI Solution Now Connects with FANUC CNC

To expand the Tool Monitoring AI Solution introduced by THK in 2022, an AI-based tool monitoring system, THK now offers connectivity with FANUC Corporation’s CNC controllers. This connectivity enables faster installation and use of the Tool Monitoring AI Solution, prevents continued operation with damaged tools, and optimizes tool replacement timing by detecting tool damage and chipping at an early stage.

Cycle data are extracted from the input signals of the CNC controller and the measurements of a current sensor installed on the drive motor. Based on this data, an AI model is generated that detects tool damage such as chipping or breakage in real time. This allows the continuous production of defective workpieces to be prevented at an early stage.

The current signals during the tool’s engagement with the workpiece are analyzed to determine the degree of tool wear and detect potential tool breakage. By identifying the optimal tool life, the replacement timing can be precisely determined, resulting in reduced downtime and tooling costs.

This solution takes a step further with the new connection to FANUC CNC controllers. Previously, it was sometimes necessary to modify the ladder diagram or manually specify the product type to read digital signals from CNC devices. With the new direct CNC connectivity, machining programs and tool numbers can now be retrieved in real time directly from the CNC controllers for smoother setup. Even in mixed-use or variable production lines where manufactured products frequently change, the system can now automatically switch to the appropriate operation mode for the current product, enabling even more precise detection of deviations.

The Tool Monitoring AI Solution is delivered as a fully integrated system, consisting of hardware components (e.g., current sensors and AI controller), communication infrastructure, and application software. This eliminates the need for individual system configuration, allowing the user to put the system into operation immediately without extensive integration work.

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