Services CNC Machine Monitoring

This section highlights a range of consultancy-led projects focused on power monitoring and process analysis within CNC machining environments. Unlike other parts of the site, the content here explores the advanced diagnostic and data-driven strategies we have developed to enhance machine efficiency, tool performance, and overall process insight.

Wireless Strain Measurement in CNC Turning

This project showcases the application of wireless passive strain sensors in a live CNC turning environment using an OKUMA LT15M machine tool.

The system was designed to monitor strain during the turning process without the need for wired connections, enabling cleaner integration and reducing interference with machine operation. By capturing real-time strain data directly from the tooling or fixture, the project demonstrated the feasibility of non-invasive, wireless process monitoring in a high-precision industrial setting.

Click here to explore the full project and learn more about the benefits of wireless strain sensing in CNC turning.

Three-Phase Power Monitoring on Hurco CNC Milling Machine

We developed and implemented a bespoke power measurement and data analysis system to monitor and characterise energy usage during CNC milling operations on a HURCO machine.

This setup records real-time three-phase power consumption throughout the machining cycle, enabling a detailed breakdown of energy usage by process stage. The collected data supports efficiency benchmarking, helps identify areas of energy waste, and informs machine tuning or operational adjustments.

Click here for more information on the system, its capabilities, and how it can be applied to your CNC environment.

CNC Broaching Process Monitoring

Advanced Strain-Based Monitoring for Broaching Applications

This innovative project focuses on a new approach to monitoring the broaching process by applying strain measurement technology directly to the broaching tool. The aim is to assess cutting forces indirectly without relying solely on traditional force dynamometers.

Project Overview

• Tool Modelling and Simulation … The broaching tool was digitised and modelled in 3D. Using simulation software, the cutting process was analysed to identify the optimal locations for sensor placement.

• Sensor Integration … Strain gauges were carefully mounted at these locations based on simulation results and practical considerations. These sensors allow for real-time force analysis during the broaching operation.

• Controlled Testing Environment … An Instron loading machine was used to push sample workpieces through the broach teeth. This setup provided a controlled environment to simulate the cutting process and evaluate the tool's performance.

• Data Capture and Comparison … Both wired and wireless strain data were collected. These results were compared with data from a standard 3-axis cutting force dynamometer to validate the accuracy and reliability of the strain-based approach.

This method offers a non-intrusive, cost-effective way to monitor broaching forces and improve process insight. Testing within an actual industrial broaching environment is the next step in this ongoing research.

Status: Simulation and bench testing complete. Industrial implementation is planned.

Real-Time CNC Machine Monitoring for Smarter Manufacturing

Our cnc router monitoring systems are designed to help CNC users improve productivity, minimise downtime and gain actionable insights from real-time data. Whether you're managing a single CNC machine or coordinating a shop floor filled with complex equipment, our software-based monitoring solutions provide the visibility and control you need to streamline operations.

By collecting and analysing data directly from your production machines, we help you track performance, monitor system status and identify bottlenecks across your manufacturing process. This includes CNC routers, mills, and other shop floor equipment, all connected to a central system for efficient monitoring.

Our monitoring software delivers:

• Real-time insights into spindle activity, feed rate, and active cycle time.

• Automatic alerts for idle time, tool changes, or error conditions.

• CNC machine tracking that helps reduce unplanned downtime and improve scheduling.

• Data-driven dashboards for visibility across your facility.

These systems support a range of use cases, from small workshops to high-output manufacturing environments. They’re ideal for factories seeking to optimise utilisation and reduce costs across every job.

If you're looking for a tailored machine monitoring solution, Stoney CNC can provide a custom system with full support, training and installation. Get in touch to learn how you can enhance your equipment performance, improve shop floor visibility, and maximise overall system efficiency.