ICOtronic
Frequently asked questions
ICOtronic is a modular process monitoring system that adapts to your needs. Depending on the application, process monitoring can be achieved with the Edge alone or extended with sensorized transceiver units and toolholders for more advanced process insights — enabling powerful analysis with minimal investment.
How can you get started with ICOtronic?
1. Start with a mobile system
Rent a mobile ICOtronic system to perform initial process analyses and evaluate the potential of process monitoring on your machines — with minimal commitment.
2. Bring process analysis in-house
Purchase a mobile ICOtronic system including analysis software for ongoing process investigations, troubleshooting and optimization within your own organization.
3. Integrate ICOtronic into your machine
For fully automated process monitoring, ICOtronic can be integrated directly into the machine and its CNC control. This enables automatic data acquisition and advanced functions such as tool breakage detection, tool wear detection and closed-loop process control, including automatic adjustment of feed rate and spindle speed. ICOtronic can be integrated with common CNC control systems such as Siemens, FANUC and HEIDENHAIN.
This step-by-step approach allows you to start small, validate the benefits and scale ICOtronic as your requirements grow.
IS ICOTRONIC Scalable and Brownfield-Compatible?
1. Start with machine signals
Begin with the ICOtronic Edge and analyze existing machine signals such as spindle speed, feed rate, power or other available machine data. This provides a first level of process monitoring without requiring additional sensors or modifications to the machine.
2. Get closer to the process
If machine signals alone do not provide sufficient insight, stationary sensors integrated into the transceiver unit can be added. This allows process-relevant physical signals to be measured directly at the machine and provides a deeper understanding of the machining process.
3. Measure directly at the tool
For the highest level of process information, sensorized toolholders can be integrated into the system. Measuring directly at the tool provides high-frequency process data and enables advanced applications such as tool breakage detection, tool wear monitoring and, ultimately, closed-loop process control.
This step-by-step approach allows you to start with the data already available, add sensor technology where needed and gradually move towards direct process measurement — without having to replace or fundamentally modify your existing machines.
Which machining processes can be monitored with ICOtronic?
- Milling
- Drilling, including deep-hole drilling
- Turning
- Grinding
Depending on the application, process data can be used not only to detect abnormalities and monitor tool condition, but also to actively optimize the machining process through adaptive feed-rate and spindle-speed control.
Can’t find the right solution for your application?
If the required solution is not covered by our existing hardware and software, we can go one step further: custom electronics and sensor solutions can be developed and manufactured specifically for your application.
This combination of process expertise, engineering capabilities and customized hardware allows us to develop solutions for virtually any machining process — even where conventional process monitoring approaches reach their limits.
Pioneers in Sensorized Toolholders
This experience gives us a deep understanding of both the machining process and the challenges of integrating electronics into rotating tools — from sensor selection and signal acquisition to data analysis and process control.
Step-by-Step Upgrade
EDGE →
Sensorized Transceiver Unit →
Sensorized Tool Holder
Fits Any Tool Holder
Independent of tool holder manufacturer.
Excellence with every Partner
Working with industry-leading partners.
100+ Optimized Processes
Proven expertise in real production.
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