# Caron Engineering > Caron Engineering designs and manufactures intelligent CNC machining automation technology—tool monitoring, adaptive control, process automation, and machine connectivity for precision manufacturers. Website: https://www.caroneng.com ## [Tool Monitoring System for CNC Machining](https://www.caroneng.com/products/tmac) # Tool Monitoring System for CNC Machining \| TMAC [Request a Quote for TMAC](https://www.caroneng.com/request-a-quote/) As manufacturing advances with automation, integrating a real-time tool monitoring system for CNC machining is essential to protect the cutting process and maintain production integrity. Caron Engineering’s TMAC 3.0 (Tool Monitoring Adaptive Control) is a powerful solution designed to detect tool wear and breakage as it happens—maximizing tool life, minimizing damage, reducing scrap, and ensuring consistent, reliable machining. Using high-resolution sensors and direct CNC integration, TMAC continuously monitors spindle motor power and other cutting parameters to monitor tool and cutting conditions at every stage of the machining cycle. When excessive wear or breakage is detected, the system reacts instantly—stopping the machine, automatically retiring worn tools, or dynamically adapting feed rates to protect the tool, part, and machine. Beyond these capabilities, TMAC captures rich data from the cutting process, enabling manufacturers to better understand tool performance, refine cutting programs, and optimize production over time. Its adaptive control functionality adjusts feed rates automatically to maintain consistent tool load, minimizing cycle time while preserving tool integrity. With TMAC, manufacturers gain a powerful advantage: real-time visibility into tool condition, process protection when operators are not present, and the insights needed to drive continuous improvement in today’s demanding manufacturing environment. [See the Results](https://www.caroneng.com/results/?_sft_product=tmac) [PDF Brochure](https://www.caroneng.com/wp-content/uploads/TMAC-Brochure-V02.2026.pdf) [More Info](https://www.caroneng.com/contact/) ## Optimize Machine Tool Cutting Performance Caron Engineering's TMAC tool monitoring system enhances cutting operations with high-precision sensors, a high-speed data processor, and an intuitive human-machine interface (HMI). The HMI visually displays each cut and the wear status of every tool in real-time, empowering users with immediate control over their cutting processes. The TMAC system's dedicated high-speed processor seamlessly coordinates communication between the tool monitoring system, sensors, and CNC control. Its robust capabilities enable the simultaneous monitoring of multiple sensors, making it ideal for managing complex machining operations and delivering rapid responses to any deviations in cutting conditions. [Adaptive CNC Tool Monitoring System: Detect Wear and Breakage in Real-time](https://www.youtube.com/watch?v=ItJT5AhdlSQ) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=ItJT5AhdlSQ) _Optimize your cutting programs, maximize tool life, and reduce cycle time with Caron Engineering's TMAC (Tool Monitoring Adaptive Control) System for CNC Machining!_ By using the learned cutting data and defining thresholds, the TMAC tool monitoring system will calculate tool wear during cutting and automatically expire a tool when excessive wear is detected or issue a signal within 5 milliseconds to stop the machine and retract the tool in the event of breakage. By accurately monitoring tool wear in real-time you can prevent unplanned equipment downtime and stop potentially catastrophic events in their tracks. This real-time control is ideal for achieving lighter and unattended operations. ## Tool Wear and Breakage Detection [TMAC Measures Work to Accurately Detect Tool Wear \| CNC Machining \| Product Highlight](https://www.youtube.com/watch?v=8PIiOHroTTk) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=8PIiOHroTTk) _TMAC calculates power over time or **work** of the cutting tool as a more accurate measurement of how the tool is wearing over time_ TMACmeasures tool wear and detects breakage by monitoring true spindle motor power. TMAC operates on the principle that the power required to cut a part increases as the tool’s cutting edges deteriorate. TMAC learns the optimum power for each tool and cutting section, and compares it to the user-defined limits to calculate wear in real-time as the tool is cutting. WORK - Measuring Tool Wear_Expand_ - With _work_, TMAC is measuring POWER OVER TIME to calculate the total power consumed over the duration of the cut - As the tool gets dull, more power is used, so the area under the curve will increase and eventually reach a wear limit indicating a tool change is required Fixed Limits - Tool Breakage Detection_Expand_ **![](https://www.caroneng.com/wp-content/uploads/TMAC_Fixed-Limits_Caron-Engineering-2-300x164.png)** - TMAC learns the peak power of the cutting tool - Alarms can be set for extreme (red), wear (yellow), and undercut (blue) per tool - TMAC will finish the current cut when a _**wear limit**_ is reached and safely expire the tool after cutting - TMAC will immediately stop the machine and retract the tool when an _**extreme limit**_ is reached - _**Undercut limits**_ can be set to alarm if not enough power was achieved based on the learned value for the cut **_Enhanced Capabilities that Set TMAC Apart:_** - Monitors and reacts to tool wear in real-time - Uses multi-range sensors with auto-scaling display sensitivity - Prevents tool breakage and lowers scrap rate - Reduces the cost of consumable tooling - Integrates with nearly any CNC and control type - Provides valuable information about the cutting process - Shows real-time data graphing as the tools are cutting - **Stops the machine and retracts tooling** instantly in the event of tool breakage or any extreme condition (see video) [TMAC Tool Monitoring in Action: Extreme Limit Response Demo](https://www.youtube.com/watch?v=o1bqwGLA6Hc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=o1bqwGLA6Hc) ## Adaptive Control Feed Rate Optimization CNC machines are often programmed with conservative feed rates to account for the worst-case machining and material conditions, sacrificing efficiency for safety. With integrated adaptive control, TMAC continuously monitors spindle load and dynamically adjusts feed rates in real time—optimizing performance within predefined limits as cutting conditions change. By learning the ideal power level for each tool and operation, TMAC maintains a consistent tool load throughout the cut. It automatically increases feed rates during low-power cuts and reduces them during high-power cuts or as tool wear progresses. This real-time adjustment maximizes cutting efficiency, minimizes cycle time, and protects your equipment from excessive load or catastrophic failure—without any operator intervention. _See how adaptive control technology works to automatically optimize feed rates during cutting!_ **The result?** Decreased cycle time, longer cutter life, and more machine uptime, especially with difficult to machine materials. [See Customer Success Stories](https://www.caroneng.com/results/?_sft_product=tmac) - Typical cycle time savings of 20 – 60% - Allows tools to run at optimum feed rates - Adjusts to variations in material, tooling, and depth of cut - Excellent for unattended/lights-out operation - Adjusts feed rates smoothly versus CAD/CAM programs that can only adjust per line in the program - Calculates tooth pass frequency to adapt to low RPM cutters ## Sensors and Components TMAC uses a dedicated high-speed data processor and has multiple integrated sensor options for total machine condition monitoring. - TMAC 3-Phase multi-range power transducers measure the power load on the tool to determine wear - Strain sensors embedded in a tool holder to measure force. - Vibration sensors are capable of measuring vibration to 22 KHZ, with adjustable sensitivity. Vibration sensors also include a built-in temperature sensor. - Other peripheral sensors can be installed and monitored by TMAC including spindle speed, coolant flow, and coolant pressure - GE P11TF12 Compliant Power Sensor_Expand_ **PT800** **POWER TRANSDUCER** - 3-phase power transducer measures the power load on the tool to determine wear - Offers high speed power analytical measurements with extremely high resolution and data rate - Auto-scaling display sensitivity adjusts for optimum sensor resolution based on the intensity of the cut. - Sample rate: 256,000 samples per second - Over 650 hp (480 kw) power handling Vibration_Expand_ **VIBRATION** - Capable of measuring vibration to 22 KHZ, with adjustable sensitivity - Used for tool wear and breakage detection, and bearing analysis - Built in temperature sensor Strain Sensor_Expand_ **STRAIN (FORCE)** - A strain gauge sensor is embedded in a tool holder to measure the force, to determine tool wear - Ideal for micro-tools - Includes built in temperature sensor Coolant Flow_Expand_ **COOLANT FLOW** - Available for a wide variety of coolant flow and pressure levels Coolant Pressure_Expand_ **COOLANT PRESSURE** - Measures coolant pressure in real time - Allows graphing of all data - Alarms if out of specification Spindle Speed_Expand_ **SPINDLE SPEED** - Accepts input from a spindle encoder or proximity switch to accurately measure spindle speed independent of the CNC control ## System Features The TMAC Tool Monitoring Adaptive Control system features an intuitive user interface that simplifies the complexity of advanced tool monitoring and adaptive control. Users can fully customize their interface views to suit specific applications, machines, or processes. For added flexibility, the TMAC interface can be accessed locally at the machine or connected to your internal network for remote access from any connected device—including smartphones and tablets. This optional, secure browser-based interface enables real-time monitoring of all TMAC systems simultaneously, safeguarded by robust, systemized security protocols to ensure safe and reliable connectivity. Multi-Channel Monitoring_Collapse_ _**Multiple sensor channels can be monitored simultaneously!![TMAC 4 Views screenshot](https://www.caroneng.com/wp-content/uploads/TMAC_4Views_Caron-Engineering-t.png)**_ For instance, you can monitor power, vibration and coolant for a specific tool and section at the same time, and have unique limits for each sensor and channel. - Create multiple custom views to look at monitoring data in different ways - View up to 4 monitoring channels in a single view - Toggle between custom views with the touch of a button - Change background color to easily identify TMAC system Remote System Access_Expand_ The new streamlined browser-based HMI allows users to access TMAC anytime, anywhere, and from any network connected device ![TMAC Devices monitor, laptop, tablet, phone](https://www.caroneng.com/wp-content/uploads/TMAC-Devices_Caron-Engineering-2100x1500-1.png) - Remotely view live cutting data from any TMAC system on your network - View all TMAC data, change job or system parameters, or access the data viewer to analyze historical cutting data from any location - Multiple users can be logged in simultaneously (with assigned permissions) Auto-Scaling Display_Expand_ TMAC learns the cut and automatically scales the display to the ideal monitoring range, for optimum sensor resolution. ![Auto Scaling TMAC](https://www.caroneng.com/wp-content/uploads/auto-scaling-tmac-caron-engineering-stacked.png) - Easily see the details of every cut, even the slightest cutting operations - The high resolution display allows the user to visualize the cuts to easily make changes and optimize cutting operations System Securities_Expand_ - Supervisors can have special privileges for advanced editing - Operators can be limited to what they can change - Remote users with more experience can change critical parameters - Anyone can view historical data ## What Else Can TMAC Do? ### Spindle Bearing Analysis A vibration sensor can be attached to the spindle, and hardwired directly to the TMAC tool monitoring system, with the bearing analysis initiated in the CNC part program. Spindle bearing analysis analyzes the vibration signal for acceleration to detect the health of the bearings and analyzes the velocity to detect any signs of misalignment, imbalance, or looseness that could result in defective parts or equipment damage. [Read More](https://www.caroneng.com/bearing-analysis/ "Read More") ### Signature Analysis The signature analysis feature in TMAC enables precise monitoring of cutting forces experienced by tooling along the exact path of a cut. This advanced capability is especially valuable for constant surface speed cutting operations, such as turning and facing on a CNC lathe, where the material diameter changes continuously. [Read More](https://www.caroneng.com/products/signature-analysis "Read More") ## Data Analysis TMAC saves and records all cutting data in a singular place, providing an intuitive interface with multiple different viewing options. The TMAC Data Viewer displays monitored data and events that can be manipulated to different formats, cutting data files that can be overlaid to provide comparative analysis, and CNC positional information to allow user inspection of CNC axis positions or spindle RPMs. TMAC Event Viewer catalogs and displays critical event data like starts, stops, alarms, or custom points in the cutting operation. As a browser-based user interface, anyone connected to the integrated network can remotely view the data obtained through the tool monitoring system. This data allows the user to interrogate specific areas of the cut to look at anomalies in the normal cutting operation. If a tool uses inconsistent power over the same cut, the user can overlay these cuts to see what is causing any anomaly. This information can also give TMAC users insight into tool life comparison between different tooling vendors and regrinds. ## TMAC Data Viewer View the details of any cut, with pan and zoom options for a closer look! - All monitored data and events are stored and can be exported in various formats for analysis - Data files can be opened simultaneously to view graphical differences - Cutting data files can be overlaid to compare cuts - CNC position data allows the user to inspect the CNC axis positions, program line number, and spindle RPM to interrogate alarms and anomalies at any point in the cut ## TMAC Event Viewer Apply custom filters to view, sort, and export events for analysis. - Displays detailed information for all events (starts, stops, alarms, etc.) - Custom events can be created to call out specific points in the cutting operation - Users can apply custom filters to view, sort, and export events for analysis ## Production Monitoring Integration **TMAC ai**, a collaboration between, **[Datanomix](https://datanomix.io/?hsa_acc=2079907119&hsa_cam=22069154848&hsa_grp=1313918848072545&hsa_ad&hsa_src=o&hsa_tgt=kwd-82121135179736%3Aloc-190&hsa_kw=Datanomix&hsa_mt=p&hsa_net=adwords&hsa_ver=3),** and **Caron Engineering**, continuously analyzes sensor data from each cut, generating adaptive models that pinpoint out-of-tolerance conditions with exceptional precision. [Learn more...](https://www.caroneng.com/tmac-ai/) OnTakt Software from Wolfram Manufacturing Technologies enables machine shops of all sizes to easily connect machines in a single dashboard to capture TMAC data, visualize operations, and react on the shop floor. [Learn more...](https://www.caroneng.com/production-monitoring/) All Caron Engineering products include the MTConnect protocol communications which allows us to provide meaningful data to any supervisory software, for real-time data sharing. --- ## [High-Speed Probe Surface Scanning](https://www.caroneng.com/probe-surface-scanning) # High-Speed Probe Surface Scanning The Probe Surface Scanning application provides a complete in-process surface analysis of any finished part. This application uses a Blum Digilog probe (see requirements below) as the sensor input and Caron Engineering’s [signature analysis](https://www.caroneng.com/products/signature-analysis/) application to scan the cutting surface and determine if, and how much, that surface deviates from a Master Part or a nominal of zero. The probe outputs measurement data at a rate of 1 sample per millisecond. This data rate allows high-speed scanning with high resolution results. The probe scans at feed rates of 600mm/min (25 in/min) and in some cases, even faster, with a resolution below 1um. Probe Surface Scanning eliminates the need for multiple probe touch points, and multiple comparisons to the nominal. The probe relies on its own calibration, not the machine position, so the probe scanning won’t be affected by any machine setup errors. Current system requirements include the Blum TC64 Digilog Probe, an RC66 receiver, IF20 interface and an EM33 module. ## Key Features - Provides rapid scanning of any surface that the scanning probe can access - Displays on-screen analysis report after every scan - In-process scanning and analysis optimizes process time - Self-calibrating probe is resistant to machine setup errors ## Products with Surface Scanning Capability CNC Sensor Analysis System [LEARN MORE ABOUT DTect-IT](https://www.caroneng.com/products/dtect-it/) ## Surface Roughness Detection --- ## [CNC In-Machine Surface Roughness Detection System](https://www.caroneng.com/surface-roughness-detection) # CNC In-Machine Surface Roughness Detection System The texture of your part's surface after machining is a critical element in achieving quality standards. Some parts demand a lower average roughness because a smoother finish is required. Other part tolerances allow an increased level of roughness because a higher texture is acceptable for the intended use of the part. No matter what the desired roughness value, by measuring the surface roughness of each machined part, we can ensure consistent quality. Caron Engineering's roughness analysis software works with a Blum-Novotest TC64 RG Digilog Probe as the sensor input to measure the surface texture. The RG probe is initiated by the CNC program to do an in-process scan of the part with the probe stylus. The roughness analysis software collects the scanned data from the probe, and using NIST traceable algorithms, calculates the surface roughness. For this analysis the probe uses a 10um radius tip to provide high resolution surface scanning. The software handles all required filtering and allows the user to set scanning parameters based on the type of surface finish being measured. The in-process measurement combined with the immediate results ensure that each part has met the quality roughness standards before it even leaves the machine. ## Key Features Using this technology in the machine, the probe can be oriented to any angle and can reach any surface that the machine can locate. The in-process measurement saves cycle time by reducing the quality steps after the part is removed from the machine. - _Verifies surfaces are free of machining errors_ - _Maintains consistent quality of finished parts_ - _Allows measuring every part with in-process roughness detection_ - _Gives insights into cutter health by measuring after each cut_ Results can be metric or imperial and include Ra, Rz, Rsm and Rmax. ## Products with Roughness Measurement Capability CNC Sensor Analysis System [LEARN MORE ABOUT DTect-IT](https://www.caroneng.com/surface-roughness-detection/) ## Caron Engineering Resources --- ## [Production Technology Center - Austin, TX](https://www.caroneng.com/resources) # Production Technology Center - Austin, TX The Caron Engineering and Wolfram Manufacturing Technologies Production Technology Center offers manufacturers a southern USA location to see the latest technologies for automation, cycle time reduction, unmanned operation, and total process monitoring and control for tool loading, offset adjustment, and more...in a real production environment! Most notably, see how the implementation of digital technologies has resulted in 24/7 production with little to no machine operator intervention or attendance. The **Production Technology Center** is a fully integrated manufacturing facility that offers a complete range of services, products and solutions for our customers. With our unique offering of technology-based solutions, we are focused on driving productivity improvements at the machine level through automation, data-driven production management systems and advanced monitoring technologies. We are a team of innovators and problem solvers, who bring diverse backgrounds, experiences and perspectives to create better solutions for our customers. We invite you to visit our production technology center to see how we can help you improve your manufacturing processes before, during, and after cutting. [Learn More or Schedule a Visit](https://wolframmfg.com/about/ptc/%20) ## Technology Center Highlights - A full production environment with thousands of hours of cutting time across CNCs, including mill- turns, lathes, mills, EDMs, broaches, and Swiss machines. - Caron Engineering products enabling fully automated production machining. - Integration of Caron Engineering products with other technologies enhancing production management. - Training programs for the Caron Engineering product line of smart manufacturing technology. - Actionable use cases to improve ROI in any production environment. Caron Engineering and Wolfram Manufacturing Technologies Production Technology Center (Austin, TX) Grand Opening was held on April 21, 2022. Check out the event recap! ## See How Wolfram Manufacturing Technologies is Using Caron Engineering Technology to Optimize Production [How DTect-IT Minimizes Scrap by Detecting Bar Feeder Vibration Early \| Product Demo](https://www.youtube.com/watch?v=yjXNlrF9j94) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=yjXNlrF9j94) #### DTect-IT Bar Feeder Vibration Detection System [ToolConnect RFID Automates Tool Loading on a FANUC Robodrill \| Product Demo](https://www.youtube.com/watch?v=PEvwfS88NsQ) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=PEvwfS88NsQ) #### ToolConnect RFID Tool Data Management System [TMAC in Action: Cutting Tooling Costs at Wolfram Manufacturing](https://www.youtube.com/watch?v=BzTZkRvqAI8) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=BzTZkRvqAI8) #### TMAC Adaptive Tool Monitoring System ## Get an Inside Look at the Production Technology Center ## CNC Sensor Analysis System --- ## [High Precision CNC Sensor Analysis System](https://www.caroneng.com/products/dtect-it) # High Precision CNC Sensor Analysis System \| DTect-IT The DTect-IT CNC Sensor Analysis System combines high-precision machine tool sensor technology with advanced analysis capability to detect and (depending on the application), correct anomalies occurring in the machining process. Using a multitude of machine tool sensor options, the user can monitor specific parameters to alarm and signal the CNC when irregularities are present. DTect-IT applications can range from monitoring high-resolution power to detect tool wear and breakage, to monitoring spindle bearing health using vibration analysis, and even detecting surface roughness using a Digilog probe sensor input. Plus, with the advanced historical viewer, all machine tool sensor and monitoring data is recorded and accessible to analyze, compare, and trend data over time. [See the Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [PDF Brochure](https://www.caroneng.com/wp-content/uploads/DTect-IT-Brochure-2026.pdf) [More Info](https://www.caroneng.com/contact/) ## DTect-IT System Overview The DTect-IT CNC Sensor Analysis System has an intuitive user interface with a graphical display that allows you to view the real-time sensor and monitoring data, and easily toggle between analyses with the click of a button. - Operates on any Windows PC with an available USB Port - Runs standalone or easily integrates with the CNC control - Multiple analyses can run simultaneously from a single sensor - Graphing and monitoring can be initialized from the user interface or the CNC control - Ideal for monitoring up to 4 tools DTect-IT monitors the high-resolution power of the cutting tools to detect wear and breakage. [Have a question about DTect-IT?](https://www.caroneng.com/contact/) ## High Precision Sensor Types The DTect-IT system communicates with machine tool sensor technology, to include: - Vibration sensors - Strain sensors - Power sensors - Analog sensors - Roughness Gauges - Scanning Probes - Audio sensors _A single sensor can be set up to run multiple analyses._ ### Machine Tool Sensor Technology Specifications Vibration (Wireless and USB Options)_Expand_ ### ![Vibration Sensor 2_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Vibration-Sensor-2_Caron-Engineering.jpg) ### **VIBRATION SENSOR (Wireless and USB Options)** - Dynamic Range:0 –32 g - Frequency Response: 100 Hz – 20 kHz at 41.667 ksps - Temperature Sensor: -40 – 85°C NTC thermistor - 40mm x 16mm (1.575 x 0.623 inch) including the anodized aluminum case Strain (Force)_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/Strain-Sensor_Caron-Engineering-1-2-300x162.png) ### **STRAIN (FORCE) SENSOR** - Capability depends on mounting characteristics - Temperature Sensor: -40 – 100°C NTC thermistor High Precision Power_Expand_ ### ![PT800 Power Sensor Caron Engineering](https://www.caroneng.com/wp-content/uploads/PT800-Power-Sensor_Caron-Engineering.png) ### **PT800** **POWER TRANSDUCER** - 3-phase power transducer measures the power load on the tool to determine wear - Offers high speed power analytical measurements with extremely high resolution and data rate - Auto-scaling display sensitivity adjusts for optimum sensor resolution based on the intensity of the cut. - Sample rate: 256,000 samples per second - Over 650 HP (480 KW) power handling Analog (0 to ±10 VDC signals)_Expand_ ### **![](https://www.caroneng.com/wp-content/uploads/Analog-Sensor_Caron-Engineering-1-300x162.png)Analog Sensor** - 4 channel inputs - 0 to ±10 VDC analog signals - 4 – 20 mA current signals - Allows monitoring with power, pressure, coolant flow, etc. Blum Scanning Probe_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/Blum-Scanning-Probe_Caron-Engineering-300x162.png) ### **Blum Scanning Probe** - Outputs data at a rate of 1 sample per millisecond - Resolution below 1 um - Self-calibrated Blum Roughness Gauge_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/Blum-Roughness-Gauge_Caron-Engineering_2-300x162.png) ### **Blum Roughness Gauge** - 10 um radius probe tip - High-resolution surface roughness scanning Audio Sensing_Expand_ **![](https://www.caroneng.com/wp-content/uploads/Windows-Microphone-1-1-300x162.png)** ### **Audio Sensing Capability** - Records from any recognized audio device on the DTect-IT Windows PC ## Sensor Analysis Types The various analysis types allow the user to analyze their CNC machine and interrogate sensor data on multiple levels. _**Analysis types include:**_ - Limit Analysis - Spindle Bearing Analysis - Fault Detection - Frequency Analysis - Signature Analysis - Data Collection Analysis Limit Analysis_Expand_ ### **![](https://www.caroneng.com/wp-content/uploads/DTect-IT_Limit-Analysis_Caron-Engineering-300x157.jpg)** ### **LIMIT ANALYSIS** - Limits available for Lower (blue), Warning (yellow), and Upper (red) - Limits can be learned automatically or set manually using the adjustable sliders - Work (area under the curve) limits can be enabled to calculate tool wear - Limits can be latched to ensure alarms are not missed - Easily detects excessive barfeeder vibration (i.e., bent bar), and signals the CNC to automatically adjust spindle RPM, if needed Analysis Compatible Sensors: _Vibration, Strain, Analog, Audio, and Power_ Spindle Bearing Analysis_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/DTect-IT_Bearing-Analysis-300x158.jpg) ### Bearing Analysis - Measures spindle vibration to monitor **bearing health** for analysis - Vibration signal is analyzed for the (1) acceleration signature which tells the health of the bearings, (2) velocity signature which detects misalignment, imbalance and looseness - Displays results within 5 seconds to let you know if attention is needed - Reports are automatically generated and saved for future analysis and trending - No baseline vibration signal required to perform the analysis Fault Detection_Expand_ ### Fault Detection - Recognizes when set upper and lower limits are exceeded, identifying an excessive condition (e.g. machine impact, extreme vibration, etc.) - Indicates and time stamps machine faults and records data on either side of the fault for analysis - Displays the peak value between starting and stopping Analysis Compatible Sensors: _Vibration, Strain, Analog, Audio, and Power_ Frequency Analysis_Expand_ ### Frequency Analysis - Magnitude limits are defined to monitor and detect anomalies within specific frequency bands - Alarms and notifications are generated when magnitude limits (in decibels) are exceeded Analysis Compatible Sensors: _Vibration, Strain, Analog, Audio, and Power_ Signature Analysis_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/Probe-Surface-Scan_Caron-Engineering-1-300x149.png) ### Signature Analysis - TMAC learns the entire path (signature) of a cut using any sensor type. - The user can define boundaries around the learned signature, both above and below it. - These boundaries define a window that the signature must stay within to satisfy a good cut. - If any portion of the monitored signature exceeds the warning (yellow) or extreme (red) boundaries, an alarm is generated. Analysis Compatible Sensors: _Vibration, Strain, Analog, Power, Roughness Gauge, Scanning Probe_ Data Collection Analysis_Expand_ ### Data Collection Analysis - Collects raw data from any sensor and stores the data to a CSV or SQLite file for analysis - Set the number of data points per second to be collected (up to 62,500 points/sec) Analysis Compatible Sensors: _Vibration, Strain, Analog, Audio, and Power_ ## DTect-IT Applications ### Bearing Analysis Using a vibration sensor attached to the spindle, DTect-IT can accurately assess the health of the spindle bearings. [Read More](https://www.caroneng.com/bearing-analysis/ "Read More") ### Signature Analysis Using the signature analysis mode, DTect-IT learns the entire path (signature) of a cut using any sensor type. [Read More](https://www.caroneng.com/products/signature-analysis/ "Read More") ### Surface Roughness Detection [Read More](https://www.caroneng.com/surface-roughness-detection/ "Read More") ### Probe Surface Scanning [Read More](https://www.caroneng.com/probe-surface-scanning/ "Read More") ## Other Prominent Applications - [![Tool Wear And Breakage](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Tool-Wear-and-Breakage_Caron-Engineering-circle.png)\\ \\ **Tool Monitoring**](https://www.caroneng.com/result/dtect-it-monitors-tool-wear-and-breakage-of-a-2-7mm-drill-and-3-05mm-reamer/) - [![DTect-IT displacement detection](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Displacement-Detection_Caron-Engineering-circle.png)\\ \\ **Temperature and Displacement**](https://youtu.be/iev7ivfQX5Q) - [![DTect-IT Collet Camp Force Detection](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Collet-Camp-Force-Detection_Caron-Engineering-circle.png)\\ \\ **Collet Clamp Force Detection**](https://youtu.be/fB6UHciMhC4) - [![DTect-IT Tool Health Check](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Tool-Health-Check_Caron-Engineering-circle.png)\\ \\ **Tool Health Check**](https://www.caroneng.com/result/tool-health-check-application-eliminates-scrap-from-runout-caused-by-chip-interference/) ## Bar Feeder Vibration Detection _Eliminate scrap and reduce spindle damage due to excessive vibration!_ - When excessive bar feeder vibration levels are detected, DTect-IT will automatically signal the CNC to reduce spindle RPM until the vibration levels are acceptable to make good parts - If RPM has to be reduced too much and parts cannot be cut, an alarm can be generated to inform the operator to stop the machine and remove the bar [Learn More](https://www.caroneng.com/products/dtect-it/#bar-feeder-vibration-detection) ## Data Viewer All monitored data is stored and can be accessed via the DTect-IT Viewer for inspection, review, and analysis. - View chart files - Trend sensor data over time for predictive maintenance - Export data for advanced analysis ## Technical Specifications Operating System Requirements_Expand_ **![](https://www.caroneng.com/wp-content/uploads/OS-1-150x150-1.png)System Requirements** - Windows 7, 10 - Linux (x86/x64/arm) Compatible Controls_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/CNC-1-150x150-1.png)Compatible Controls - Fanuc - Okuma - Mitsubishi - Siemens - Citizen - Heidenhain - Fagor - Brother - Makino - Mazak Stored Data Format_Expand_ ### ![](https://www.caroneng.com/wp-content/uploads/Stored-Data-1-150x150-1.png)Stored Data Format - CSV - SQLite - XML Communication Protocols_Expand_ **![](https://www.caroneng.com/wp-content/uploads/IO-150x150-1.png)Available Communication** - RS232 - TCP/IP Ethernet - Physical I/O – Ethernet - Physical I/O – USB All Caron Engineering products include the MTConnect protocol communications which allows us to provide meaningful data to any supervisory software, for real-time data sharing. ## MiConnect Technology Overview --- ## [MiConnect Technology: The Ultimate Cell Controller for Manufacturing Automation at EASTEC 2025](https://www.caroneng.com/events/miconnect-technology-automation-cell-controller) # MiConnect Technology: The Ultimate Cell Controller for Manufacturing Automation at EASTEC 2025 **LIVE CUTTING DEMO IN BOOTH 5359** Don’t miss the chance to see [MiConnect](https://youtu.be/z50v9qlUyQg?si=atfHFLCCFxRtWSRU) and Caron Engineering’s smart manufacturing product suite in action on our fully automated production cell at EASTEC 2025 in West Springfield, MA. The live cutting demo will feature a bar feeder fed Tsugami Swiss lathe, equipped with adaptive tool monitoring to automatically optimize cutting. This demo will also feature a post-process automation cell with a collaborative robot, air-actuated parts cleaner, vision gauging, and automated feedback for tool wear compensation sent directly to the control. In addition to MiConnect, explore Caron Engineering’s full range of smart technologies designed to elevate automation, process control, and machine productivity in Booth 5359, including TMAC, AutoComp, ToolConnect, DTect-IT and Smart Light. ## Tool Data Management --- ## [RFID Machine Tool Data Management System](https://www.caroneng.com/products/toolconnect) # RFID Machine Tool Data Management System The ToolConnect machine tool data management system eliminates human error and reduces setup time by automating the transfer of presetter measured tool data to (and from) the CNC control. ToolConnect reads and processes RFID and 2D barcode data and updates offsets automatically; _no operator data-entry or interaction with the CNC control needed!_ Each ToolConnect system is uniquely configured to meet the customer’s requirements and tool load process specifications. [Have a question about ToolConnect?](https://www.caroneng.com/contact/) ## ToolConnect: RFID System [![MiConnect Logo](https://www.caroneng.com/wp-content/uploads/MiConnect-Logo-1-300x42.png)](https://www.caroneng.com/miconnect-technology/) The ToolConnect RFID Tool Data Management System automatically transfers tool presetter measurement data directly to and from the CNC control via RFID tags embedded in tool holders. - Tools are measured at the presetter where tool data is written to the RFID tag - The tool is placed in a custom RFID read station at or inside the CNC machine and all tool data is read and processed by ToolConnect - The ToolConnect user-interface guides the user through the required (customer-defined) steps and confirms successful completion before allowing the user to proceed to the next step - ToolConnect reads and writes data to the CNC control; automatically updating tool offsets and tool life data to (and from) the RFID tag ### RFID System Includes: - ToolConnect software - A custom-designed tool pot (read station) for the proper tool holder type - A tool ID controller with read/write head - An 8″ touch screen PC for user prompts and information ## ToolConnect: 2D Barcode Scanning System The ToolConnect 2D Barcode Scanning System automatically transfers tool presetter measurement data directly to the correct fields in the CNC control via 2D (presetter) printed barcode tags. - Tools are measured at the presetter where the tool data is printed to a barcode tag - 2D barcode scanner scans the barcode at the machine - ToolConnect processes and displays the scanned data - ToolConnect guides the user through the required tool load steps and updates tool and offset information in the control automatically [Watch the Video](https://youtu.be/QyFAkyWijqk) [![MiConnect Logo](https://www.caroneng.com/wp-content/uploads/MiConnect-Logo-1-300x42.png)](https://www.caroneng.com/miconnect-technology/) ### 2D Barcode System Includes: - ToolConnect software - 2D barcode scanner - An 8″ touch screen PC for user prompts and information ## Benefits - Automates the process of loading and unloading tools - Reduces setup time and improves productivity - Ensures consistent and accurate process flow - [Eliminates operator errors](https://www.caroneng.com/success-stories/toolconnect-rfid-tool-identification-success-story) by automatically updating offsets in the control - Verifies the correct tool is being loaded into the machine - Provides a common user-interface for every CNC machine on the shop floor - Eliminates the need for a post-processor - Maximizes chip cutting time by using offline tool setting ## System Features - Works with nearly any presetter that can write to an RFID tag or print a 2D barcode - Easily integrates with almost any machine and control type - Intuitive operator screens display all tool information and guide the user throughthe process flow, ensuring each step is successfully completed - The flexible design of the software can easily accommodate changes to the process - MTConnect Compliant ### THE DATA: ToolConnect Audit Log - Every step, action, and data exchange is logged with date and time stamp - Data is available locally or via MTConnect - This data is valuable for quality control and process verification ## Advanced Tool Tracking ToolConnect now goes beyond automated tool loading by providing real-time reporting to supervisory systems for advanced CNC tool tracking, giving you: - **Complete visibility** of tool locations, tool life status, and overall asset tracking across the shop floor. - **Accurate tool usage monitoring** to prevent premature tool changes. - **Optimized inventory management** that reduces waste and boosts efficiency by eliminating manual data entry. The flexibility of ToolConnect allows shops to expand their tool management processes as production demands evolve, making modifications without major system overhauls. ## Customized Process Flow The guided process flow of each ToolConnect machine tool data management system is unique to the user’s tool load specifications. - Prompts the user through the process flow - Forces and verifies steps - Will not let the incorrect tool be loaded - Sends data directly to the CNC control ## Standard Control Interface - Fanuc (Focas ½) - Okuma P controls - Heidenhain - Mitsubishi - Siemens 840D - Mazak - Fagor - Makino - Brother - Haas [Streamline Tool Setup with ToolConnect RFID \| FANUC Robodrill Demo](https://www.youtube.com/watch?v=mYGCAqWzWuE) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=mYGCAqWzWuE) [Barcode ID System for CNC Tool Tracking and Data Management \| Product Demo](https://www.youtube.com/watch?v=QyFAkyWijqk) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=QyFAkyWijqk) [RFID User Authentication: Enhancing Manufacturing Security \| Caron Engineering](https://www.youtube.com/watch?v=l_lVU70P0F0) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=l_lVU70P0F0) All Caron Engineering products include the MTConnect protocol communications which allows us to provide meaningful data to any supervisory software, for real-time data sharing. ## Tool Wear Monitoring Systems --- ## [Robotics Integration for CNC Machining](https://www.caroneng.com/robotics-integration-cnc-machining) # Robotics Integration for CNC Machining Robotics integration for CNC machining is crucial for realizing complete automation in manufacturing production. Effectively incorporating robotics for machine tending to align with CNC and other automation systems serves as a strategic approach to automate processes and improve overall efficiency. While the fundamental functions of robot control, safety prioritization, and proper functioning are covered by robot brands' programming software, extending communication beyond the immediate cell poses significant challenges. Many existing solutions lack the capabilities required for connecting with other devices, databases, or interacting with supervisory systems. Additionally, limitations in control parameters and adaptability to changing processes often hinder the full potential of robot machine tending integration. ## Connecting Automation Caron Engineering’s [MiConnect Technology](https://www.caroneng.com/miconnect-technology/) combats the many challenges of integrating robot arms into your operations, including CNC and automation device compatibility, limitations for complexity, and flexibility and adaptability to changing processes. MiConnect is a customizable application builder tailored for manufacturing, enabling the seamless connection and control of all devices in your manufacturing environment. Within the MiConnect "toolbox," you'll find an inventory of pre-built manufacturing devices including the ability to communicate to CNC controls, robot arms, electronic measurement devices, barcode readers, files, databases, supervisory systems, and much more. [Seamless Machine Tending Integration Using MiConnect \| Caron Engineering \| Product Demo](https://www.youtube.com/watch?v=rb-UV6vUSow) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=rb-UV6vUSow) _See how MiConnect enables communication and control of all the devices in this post-machining automation cell!_ [Have a question about Machine Tending Integration with MiConnect?](https://www.caroneng.com/contact/) ## A Software-Centric Solution for Post-Machining Automation For machine tending robotic integration for CNC machining, MiConnect serves as a software-centric solution. It facilitates the connection of your robot arm with various CNC or automation devices to interact with each other by using the drag-and-drop building blocks of operations to customize your manufacturing process. For example, when a robot unloads a part from a machine, and presents it to an electronic gauge for measurement, MiConnect can signal the gauge to begin the measurement process. Upon completion, MiConnect will signal the robot to unload the part and then will send the data upstream for automated tool wear compensation back to the CNC control. ## Seamless Communication and Connectivity **Robots lack compatibility and device communication.** Not all robot arms and automation can connect to all controls. Specific communication protocols are required per control which limits compatibility. MiConnect can create any robot as a device and any CNC as a device to pull in all the registers associated with the control to be used within the platform. This allows for a seamless integration between the robot arm and the control. The user can then use the platform to program the robot arm and control it from a single interface. MiConnect can also be used to connect older machines that have no industrial protocols. **Robots lack the ability to read databases.** When a robot is tasked with loading a job into a machine, there are databases linked to that specific job, such as the part program for cutting or the CMM measuring device program for identifying the required feature measurements. The robot is unable to interpret this data. Moreover, if the database needs to be transmitted upstream to a production monitoring system, the robot faces challenges in connecting or communicating with such a system. However, MiConnect Technology simplifies this process, allowing for seamless communication and connectivity. ## MiConnect Streamlines Human Interaction for Complete Process Control **MiConnect streamlines user interaction** by providing a singular, user-friendly interface for programming all device communication. The MiConnect HMI displays each step in the process and is customized to display any user defined steps and instructions for the operator to complete before the process advances. Additionally, MiConnect ensures process integrity by systematically logging all interactions. It has the capability to retrieve necessary data from files or databases and transmit data upstream to supervisory systems, enabling comprehensive integration for total production monitoring. **Processes change.** The MiConnect platform was created with flexibility and adaptability to ever-changing processes in mind. This empowers manufacturers to create a more versatile and responsive production environment. ## Why MiConnect for Machine Tending? Before the introduction of MiConnect, manufacturers had to either develop their custom software or seek third-party applications to integrate machine tending functionalities with external systems. This adaptability is essential, particularly when robots require interaction within the broader manufacturing environment or with other interconnected systems. By providing a solution for robots to communicate beyond their immediate environment or cell, MiConnect contributes to the efficiency and adaptability of robotic systems within manufacturing processes. It offers a more user-friendly and standardized approach to robot integration, reducing the burden on manufacturers to develop custom solutions for each combination of robot arms and control systems. By creating a standardized communication platform, MiConnect enables easy integration between robot arms and all other device communication in your process. As industries continue to embrace the era of automation, the role of machine tending cannot be overstated. Caron Engineering's [MiConnect Technology](https://www.caroneng.com/miconnect-technology/) serves as a catalyst for overcoming the challenges associated with machine tending integration, offering a comprehensive software-centric solution. By ensuring compatibility, flexibility, and a streamlined integration process, MiConnect empowers manufacturers to unlock the full potential of their automated production systems, marking a significant step towards the future of manufacturing efficiency. [Contact Us to Learn More](https://www.caroneng.com/contact/ "Contact Us to Learn More") ## Related Products ### Streamlined Process Automation Software ### Automated CNC Offset Control Software ### RFID Tool Data Management System ## Cycle Time Reduction --- ## [Manufacturer Cuts Cycle Time by 41% with TMAC’s Adaptive Feed Rate Control](https://www.caroneng.com/result/customer-reduces-cycle-time-by-41-using-tmac-adaptive-control-feed-rate-optimization) # Manufacturer Cuts Cycle Time by 41% with TMAC’s Adaptive Feed Rate Control | | | | --- | --- | | **Industry:** | Transportation | | **Machine:** | HMC | | **Material:** | Compact Graphite Iron | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge A customer is machining compacted graphite iron engine block components. They have two large identical horizontal machining centers running the same part and process. Both machines are running 6 parts per shift. They were exploring new technology to help enhance production. With the identical machines running the same process it gave them the ability to run a controlled comparison to their original process. ## Solution The customer implemented Caron Engineering’s [TMAC (Tool Monitoring Adaptive Control) System](https://www.caroneng.com/products/tmac/) on one of the two identical horizontal machining centers. The machine running TMAC saw an immediate cycle time reduction of 25% using the adaptive control option. Adaptive control automatically adjusts the feed rate based on the material conditions to optimize cutting time. In addition, the operators were performing multiple critical checks throughout the process. With TMAC, these manual checks were no longer needed since TMAC runs these checks in real time. TMAC automatically calls a redundant tool when it detects excessive tool wear, allowing the machine to run unattended. By eliminating these manual checks and gaining the ability to run the machine unattended, cycle time on this part was reduced by an additional 16%. The implementation of [TMAC](https://www.caroneng.com/products/tmac/) on this machine resulted in a total cycle time savings of 41%. They are now producing 10.2 parts per shift, compared to only 6 on the identical HMC without TMAC. This customer ### Results - Reduced cycle time by 41% - Allowed unattended operations - Customer immediately ordered 9 more [TMAC](https://www.caroneng.com/products/tmac/) systems [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/6120_Customer-Reduces-Cycle-Time-by-41-Using-TMAC-Adaptive-Control-Feed-Rate-Optimization.pdf) ## Contact Caron Engineering --- ## [Contact Us!](https://www.caroneng.com/contact) # Contact Us! Please contact us by phone, email, or the form on this page. **Caron Engineering** 116 Willie Hill Road Wells, Maine 04090 USA **Phone:** [+1 (207) 646 6071](tel:+1(207) 646 6071) **Fax:** [+1 (866) 876 7175](tel:+1(866) 876 7175) **Email:** [marketing@caroneng.com](mailto:marketing@caroneng.com) ## Contact Form - \\* Required Field - Name\* FirstLast - Email\* - Phone\* - Stay Connected Via SMS Messages - [ ] I give my consent to receive SMS messages from Caron Engineering. 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I'm not a robot reCAPTCHA - Email Notifications ## CNC Integration Solutions --- ## [CNC Systems Integrators](https://www.caroneng.com/integrators) # CNC Systems Integrators \| Caron Engineering Products Caron Engineering has a worldwide network of qualified companies that specialize in the integration of their smart manufacturing technology. Each representative company is fully trained to sell and install all Caron Engineering solutions while upholding the highest standards for customer satisfaction. - ![Integrator Map_United States_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Integrator-Map_United-States_Caron-Engineering-1-scaled.jpg) ## United States - ![Caron Engineering Worldwide Integrator Map](https://www.caroneng.com/wp-content/uploads/caron-worldwide-integrator-map.png) ## Worldwide [Contact Us to Connect with Your Local Systems Integrator](https://www.caroneng.com/contact/ "Contact Us to Connect with Your Local Systems Integrator") ## CONTINENTAL US ### Newman M2M Located in Rock Hill, South Carolina, Newman M2M has been offering full-service integration solutions for manufacturing since 2011. Owner, Bryan Newman, has in-depth experience in manufacturing and information technology and has built his reputation on providing quality systems integration services for his customers. Territory: SC, NC, VA, MD, DE, WV, TN, GA, AL, MS, AR, FL [Visit Website](http://www.newmanm2m.com/ "Visit Website") ### Blum-Novotest Blum-Novotest, Inc., is a fully owned subsidiary of Blum-Novotest GmbH, a leader in cutting edge measurement and testing technology, with more than 50 years of experience as a supplier for the worldwide machine tool, automotive and aircraft industries. Territory: KY, IN, IL, MN, WI, IA, ND, SD, Canada and Mexico. Worldwide: Blum-Novotest GmbH [Visit Website](https://www.blum-novotest.com/us/ "Visit Website") ### Wolfram Manufacturing Established in 2011, Wolfram Manufacturing is an extremely versatile machine shop that specializes in medium to high volume production of metal parts. Wolfram focuses on using the best technology manufacturing has to offer and appealing to the next generation of makers. In 2022, Wolfram Manufacturing opened its doors as a [Production Technology Center](https://www.caroneng.com/wolfram-production-tech-center/) to see Caron Engineering technology in action. Territory: TX, MO, OK, KS, NE, NM, CO, WY, MT, ID, UT, AZ, CA, NV, OR, WA [Visit Website](https://wolframmfg.com/ "Visit Website") ### Prime Technical Services Prime Technical Services, Inc. specializes in intelligent manufacturing with the integration of high-quality products for machines tools to help you compete in the global market. Since 2007, they have specialized in optimizing productivity for manufacturing to drastically reduce set up time, cycle time, and make it possible to run unmanned or "lights-out" operations. Territory: OH, western PA, western NY [Visit Website](https://primetsi.com/ "Visit Website") ### Ovation Engineering Ovation Engineering was established as a sole proprietorship in 1991 and subsequently incorporated in 1993. Ovation has provided support to manufacturing automation with software and hardware focused on measuring systems, automation and CNC machine enhancements for safety and productivity. Territory: MI [Visit Website](https://ovationeng.com/ "Visit Website") ### Serview Serview is a systems integrator that provides a variety of services to industrial manufacturing companies. Established in 1999, they are a family-owned business, located in West Berlin, NJ. They provide solutions to clients using advanced industrial automation technologies. Their systems and products are in use worldwide for manufacturing of mass-produced items where quality is critical. Territory: NJ, Eastern PA [Visit Website](https://www.serview.net/ "Visit Website") ## WORLWIDE REPRESENTATION ### Blum-Novotest GmbH Territory: Mexico, Canada, Europe, Asia, South America, Africa [Website](https://www.blum-novotest.com/df/) ### Electronic Gauging Solutions Territory: Australia [Website](http://www.electronicgaugingsolutions.com/home) ## CARON ENGINEERING PRODUCTS Our CNC system integrators are experts in Caron Engineering's smart technology solutions for tool monitoring, automation, and process control. With an intricate understanding of Caron Engineering's suite of products, our integrators excel in seamlessly integrating these solutions into your CNC systems, ensuring optimal performance, efficiency, and productivity. Tool Monitoring Adaptive Control Automated Tool Wear Compensation CNC Sensor Analysis System Tool Data Management System Automation Software for Machining Intuitive Machine Status Light --- ## [Caron Engineering Video Resources](https://www.caroneng.com/resources/videos) # Caron Engineering Video Resources [Caron Engineering Company Video ~ Smart Manufacturing Solutions](https://www.youtube.com/watch?v=kyud8Pl0Grs) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=kyud8Pl0Grs) ## Company Video Get an inside look at our facility, our people, and our smart manufacturing technology. Caron Engineering is an employee-owned company providing leading smart manufacturing solutions to reduce cycle times, promote unattended operation, drive down tooling costs, and minimize expensive damage to machines and work-holding. Caron Engineering has been developing technology for the CNC manufacturing industry since 1986. [Download our Brochure](https://www.caroneng.com/wp-content/uploads/Caron-Engineering-Company-Brochure-V06.2022.pdf) ## Product Videos ## TMAC 3.0 - New Features for Enhanced Tool Monitoring Optimize your cutting programs, maximize too life, and reduce cycle time with Caron Engineering's TMAC (Tool Monitoring Adaptive Control) System for CNC Machining! [Watch More TMAC - Tool Monitoring Adaptive Control - VIDEOS](https://www.youtube.com/playlist?list=PLv76g7BsLHklXaq62SKTcwUmd9KBTubSi) [Advanced Tool Wear and Breakage Detection System for CNC Machining](https://www.youtube.com/watch?v=RlnBN8TmcRY) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=RlnBN8TmcRY) [MiConnect Technology: Simplifying Manufacturing Automation \| Product Introduction](https://www.youtube.com/watch?v=z50v9qlUyQg) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=z50v9qlUyQg) [See More MiConnect - Automation Software for Machining - VIDEOS](https://youtube.com/playlist?list=PLv76g7BsLHklfU5crjvznK3-QFQUb4EwU&si=l5N1ZqDHpTqJeeF4) [ToolConnect Introduction: Automating CNC Tool Identification with RFID & Barcode Systems](https://www.youtube.com/watch?v=cwy3SJfvy0c) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=cwy3SJfvy0c) [See More ToolConnect - CNC Tool Identification and Data Management System Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHkn9I0bYpnHO0Uvxzv522O9J) [Automated Tool Wear Compensation on OKUMA LB3000 \| AutoComp Demo](https://www.youtube.com/watch?v=DgciIpVHqYI) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=DgciIpVHqYI) [See More AutoComp - Tool Wear Compensation Software (CNC) Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHkmvMqibGvE8sXuuifV9pqHz) [DTect-IT: CNC Spindle Bearing Monitoring with Vibration Sensor Analysis](https://www.youtube.com/watch?v=S6Nhe89Kebc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=S6Nhe89Kebc) [See More DTect-IT - CNC Sensor Analysis System Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHknzmmJuJTQ8HaEw7swEjwc-) [Smart Light - Fully Customizable CNC Machine Status Light (Caron Engineering)](https://www.youtube.com/watch?v=LSJNHcBSHn4) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=LSJNHcBSHn4) ## Caron Engineering Technology Videos [FANUC Robodrill CNC with Caron Engineering Solutions \| Fully-Automated High Speed VMC Demo](https://www.youtube.com/watch?v=GO5zRtRDprc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=GO5zRtRDprc) [See More Fully-Automated Machining Demonstration Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHkkQ0t0q88Zm3jY9ruA0R2kK) [DTect-IT & AutoComp keep those spindles turning](https://www.youtube.com/watch?v=uuuRbR-7ja0) [MTDCNC](https://www.youtube.com/channel/UC09R-RDOwz88FqD--3YWmew) MTDCNC220K subscribers [Watch on](https://www.youtube.com/watch?v=uuuRbR-7ja0) [See More TONY GUNN Videos with Caron Products](https://youtube.com/playlist?list=PLv76g7BsLHkn4mAg0D6LRw95B7UQNZUiZ) [Automated, Lights-Out Machining on a Tsugami TMA8F \| Caron Engineering](https://www.youtube.com/watch?v=9y2fvw-87Qg) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=9y2fvw-87Qg) [See More IMTS Caron Engineering Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHklCneRWkItq8ZaxyODnLVqL) [How to Achieve Lights-Out Machining with Smart Technology \| Rob Caron](https://www.youtube.com/watch?v=mdvpC5sNvJU) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=mdvpC5sNvJU) [See More Webinar Videos](https://www.youtube.com/playlist?list=PLv76g7BsLHklAS9c-TSyD5xRVLQRp6Ueb) [Testimonial \| Caron Engineering Technology Optimizes Machining Productivity at Orizon Aerostructures](https://www.youtube.com/watch?v=tWS4gnu_ErQ) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=tWS4gnu_ErQ) [Event Recap! Caron Engineering Production Technology Center Grand Opening \| Austin, TX](https://www.youtube.com/watch?v=RA4HEKmr6Lc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=RA4HEKmr6Lc) ## Industries Served --- ## [Caron Engineering - Industries Served](https://www.caroneng.com/industries) # Caron Engineering - Industries Served Our products serve a wide range of manufacturing industries. With the versatility to communicate with almost any CNC control on the market, regardless of builder, our technology is expansive in its manufacturing capabilities. From the precision machining of small medical components to the difficult-to-machine materials of aerospace and defense, our solutions will help you optimize production to maintain the integrity of your machined parts. ## Aerospace ## Heavy Equipment ## Oil and Gas ## Automotive ## Weapons and Defense ## Medical # Providing Service to a Wide Range of Clients ## Adaptive Tool Monitoring System Adaptive Tool Monitoring System Caron Engineering'sTMAC (Tool Monitoring Adaptive Control) system interfaces directly with almost any CNC control, optimizing the machining process, to improve performance, productivity,andproftability. TMAC uses high resolution sensor data to measure tool wear in real-time. With its direct interface to the CNC control,TMAC makes automatic and instantaneous, corrective adjustments without the need for human intervention. TOOL MONITORING FOR WEAR AND BREAKAGE TMAC reduces the high costs associated with broken tools, lost production, and rejected parts by measuring tool wear in real-time. Maximizes tool life Prevents tool breakage and lowers scrap rate Reduces the cost of consumable tooling Graphically displays all cutting data for analysis Sends remote notifcations of machine alarms $ODUPV IRU H\[WUHPH ZHDU\ DQG XQGHUFXW\ OLPLWV SHU WRRO\ \ Typical cycle time savings of 20 - 60%\ \ Adjusts to variations in material and tooling\ \ TMAC learns the optimum power for each tool and continuously maintains a constant tool load by automatically adjusting the feed rate in\ real-time. The result? Decreased cycle time, longer cutter life, and more machine uptime, especially with diffcult to machine materials.\ \ Adjusts feed rates smoothly versus CAD/CAM programs that\ can only adjust per line in the program\ \ ADAPTIVE CONTROL FEED RATE OPTIMIZATION\ \ Calculates tooth pass frequency to adapt to slow RPM cutters\ \ P +1 (207) 646-6071\ E [marketing@caroneng.com](mailto:marketing@caroneng.com)\ \ * * *\ \ SENSOR TECHNOLOGY\ \ Power, Vibration, and Strain sensors can all be used by TMAC to measure tool wear. Other sensors can be installed and monitored by TMAC including spindle speed, coolant flow, and coolant pressure\ \ POWER TRANSDUCER\ \ 3-phase, multi-range power transducer measures the power load on the tool to determine wear\ \ High speed power analytical measurements with extremely high resolution and data rate\ \ STRAIN SENSOR\ \ A strain gauge sensor is embedded in a tool holder to measure force\ \ - Includes built in temperature sensor\ \ Multiple sensor options for TOTAL MACHINE CONDITION MONITORING\ \ A vibration sensor can be attached to the spindle, hardwired to TMAC, with the bearing analysis initiated in the CNC part program.\ \ VIBRATION SENSOR\ \ Capable of measuring vibration to 22 KHZ, with adjustable sensitivity\ \ Includes built in temperature sensor\ \ COOLANT FLOW\ \ - Results displayed within 5 seconds\ \ SPINDLE SPEED\ \ - Reports are saved for analysis\ \ COOLANT PRESSURE\ \ Spindle Bearing Analysis\ \ GE P11TF12 Compliant\ \ The user can define boundaries around the learned signature, both above and below it\ \ Signature Analysis\ \ - These boundaries define a window that the signature must stay within to satisfy a good cut\ \ If any portion of the monitored signature exceeds the warning (yellow) or extreme (red) boundaries, an alarm is generated\ \ * * *\ \ DATA ATYOUR FINGERTIPS\ \ The browser-based user interface allows users to access the TMAC\ system anytime, anywhere, and from any network connected device!\ \ Data all in one place\ \ Intuitive streamlined interface with multiple viewing options\ \ Remotely view live data from any TMAC system on your network\ \ Seamless communication with third party OEE software\ via the industry standard protocol\ \ EVENT & DATA VIEWERS\ \ All monitored data and events are stored and can be exported in various formats for analysis\ \ CNC position data allows the user to inspect the CNC axis positions and program line number; to interrogate alarms\ and anomalies during cutting\ \ Cutting data can be overlaid to compare cuts\ \ Apply custom flters to view,\ sort, and export events for\ analysis.\ \ TMAC MONITORS MULTIPLE\ PROCESSES\ AND SENSOR CHANNELS\ SIMULTANEOUSLY\ \ View the details of any cut,\ with pan and zoom options for\ a closer look!\ \ FEATURES AND BENEFITS\ \ Automatic real-time data graphing\ \ Increased machine tool utilization with less downtime\ \ Auto-scaling display sensitivity for optimum resolution\ \ Universal interface easily adapts to CNC controls\ \ Programmable to call a redundant tool when a wear limit is\ reached (control dependent)\ \ Easily monitors tapping cycles\ \ Eliminates air cutting using the APPROACH FEED RATE feature\ \ * * *\ \ #### SMARTMANUFACTURINGSOLUTIONS\ \ ### Monitor multiple different TMAC systems on multiple different machines... ...all from ONE browser!\ \ # OTHERPRODUCTSFROMCARONENGINEERING\ \ poweredby\ \ #### AllCEIproductsare compliant\ \ ## [www.caroneng.com](http://www.caroneng.com/)\ \ Please visit our website for the most up-to-date information Caron Engineering,Inc. P +1 (207) 646-6071 116 Willie Hill Rd. V.072022 E [marketing@caroneng.com](mailto:marketing@caroneng.com) Wells,Maine 04090 USAMADEINTHEU.S.A. ## Production Monitoring Solutions --- ## [Automated Production Monitoring Integration](https://www.caroneng.com/production-monitoring) # Automated Production Monitoring Integration Production monitoring technology for manufacturing has become increasingly important to get a consolidated view of what's happening on your shop floor. The software can show you the status of the machines, but also the status of the integrated technology that is connected to the machines. This capability can help you make better decisions about your processes and also let you see the status of all shop floor assets at a glance, to ultimately, reduce downtime and increase efficiency. Caron Engineering's products create a lot of data for analytics and process improvements. This data can be effectively integrated and monitored using both the Datanomix platform and Wolfram Manufacturing's Ontakt production monitoring software. # DATANOMIX + Caron [Datanomix](https://datanomix.io/), an automated production intelligence platform, and Caron Engineering have partnered to jointly develop data-driven solutions that leverage the companies’ manufacturing domain expertise in real-time production monitoring and machine tool optimization. This integration adds a new dashboard in the Datanomix platform that aggregates and displays the metrics for all Caron Engineering devices deployed in a factory. The ultimate goal of the partnership between Datanomix and Caron Engineering is to address the immediate needs of manufacturers looking to take proactive measures in optimizing and improving all facets of their facility. Combining the advanced analytics and machine learning capabilities of Datanomix and the impressive sensor technology and signal processing techniques of Caron Engineering leads to more profitable performance for all companies that choose to integrate automated production monitoring tactics. Based in New Hampshire, Datanomix provides real-time production monitoring and performance analytics for CNC machines, without the need for operator inputs or links to ERP systems. Datanomix has created the next generation of production monitoring, called Automated Production Intelligence. By integrating and analyzing Caron Engineering tool performance and optimization data, Datanomix delivers deeper insights, giving you visibility from the tool to the machine to the overall factory. [_Learn more about the integration of our solutions!_](https://datanomix.io/caron-integration/) The Datanomix TMAC dashboard represents the first offering from the integration between Caron Engineering and Datanomix. The Datanomix data science team is currently analyzing Caron performance data to create new machine learning algorithms that will deliver deeper insights, from the tool to the machine all the way to overall factory production. [Read the Press Release](https://www.caroneng.com/news/datanomix-and-caron-engineering-partner-to-deliver-real-time-performance-intelligence-for-precision-manufacturers/) # ONTAKT + CARON [Wolfram Manufacturing's](https://wolframmfg.com/), OnTakt Software, enables machine shops of all sizes to easily connect machines in a single dashboard to capture data, visualize operations, and react on the shop floor to manage production in real time. This lightweight software provides an approachable and easily integrated lightweight software that meets the needs of small to medium-sized machine shops. Wolfram Manufacturing believes that all shops should be able to implement new technologies that facilitate simple and intuitive management of shop floor activities. OnTakt enables any shop to proactively make decisions as issues arise, not after the fact. Built with scale in mind, OnTakt provides accessible real-time data and powerful results for shops with as few as five employees and grows in function to provide the advanced customizable features needed for shops with several hundred employees. [Learn More](https://wolframmfg.com/products/ontakt/) OnTakt and [TMAC](https://www.caroneng.com/products/tmac/) from Caron Engineering are designed to be tightly woven to offer comprehensive automated production monitoring integration. Leveraging data from both systems simultaneously leads to significant savings on tooling. TMAC tool monitoring software is an essential requirement to protect machines from damage, maximize tool lifespan, and reduce the cycle times that lead to a higher throughput. Adaptive control from TMAC intuitively derives the optimized power for individual tools and maintains consistent tool loads by providing an instantaneously adjusted feed rate during operation. By pairing TMAC with the valuable tool life data tracked and recorded in OnTakt, we can easily identify trends to decide when to look into poorly performing tools or identify process changes that need attention. This type of data is often lost on a shop floor. However presenting it clearly, to all levels of an organization, can lead to significant cost savings with rapid ROIs. OnTakt and TMAC will quickly pay for themselves after finding even one tool that could benefit from a more aggressive tool life. ## Related Content ### Wolfram Production Technology Center ### Adaptive Tool Monitoring System ### RFID Tool Data Management System ## TMAC Version 3.0 --- ## [The New TMAC Version 3.0: Machine Tool monitoring, Optimization and Control](https://www.caroneng.com/news/the-new-tmac-version-3-0-machine-tool-monitoring-optimization-and-control) # The New TMAC Version 3.0: Machine Tool monitoring, Optimization and Control _![](https://www.caroneng.com/wp-content/uploads/TMAC-Devices_Caron-Engineering-1-300x236.jpg)Adaptive Tool Monitoring System with Real-Time Machine Control_ Caron Engineering has announced a major update release of their Tool Monitoring Adaptive Control system, TMAC version 3.0. TMAC has been a distinguished manufacturing optimization solution for over 30 years, with its advanced monitoring and adaptive control capabilities. TMAC is a real-time tool wear detection system that uses high-precision, multi-range sensors to determine if a tool is worn or broken. Caron Engineering sensors are 10 times more sensitive than other sensors on the market, allowing TMAC to cover a wider range of tools. TMAC has a separate high-speed processor that collects data at 200 times per second, and directly interfaces with any CNC control, to react instantly to wear and extreme conditions. TMAC 3.0 has been completely redesigned with an intuitive streamlined user-interface that offers numerous configurations for viewing tool monitoring and sensor data. The TMAC system processor now houses its own web server, making the HMI (human-machine interface) browser-based, which enables real-time monitoring from any network connected device. Users (with assigned permissions) have live access to all TMAC systems on a shop floor from a single browser. Securities and permissions can be customized for each user to assign system access based on their user role and job function. TMAC has an adaptive control mode that optimizes cutting with changing conditions due to wear, variations in material hardness, consistency, and depth of cut. Using a power sensor to monitor motor power, TMAC overrides the machine tool feedrate to maintain a constant spindle motor power during cutting. This enables TMAC to increase the feedrate with low power cuts and decrease with high power cuts, and as tools wear. No operator intervention is necessary when TMAC is monitoring and controlling, making it ideal for unattended operations. Users will see an immediate increase in productivity, extended tool life, and overall reduction in cycle time (up to 60%). Cycle time savings are most significant with hard and difficult to machine materials. In addition to power, TMAC monitors sensors for vibration, strain, coolant pressure and flow, and spindle speed. The newly enhanced HMI has expanded the monitoring capabilities with TMAC. Users can customize views to show up to 4 sensor channels simultaneously in a single view. For example, the user can set up a single (split-screen) view to monitor power, vibration, spindle speed, and coolant for a specific tool and section at the same time; and have unique limits for each sensor and channel. A user can create unlimited views to show data in a variety of ways, and easily toggle between views during monitoring. Using a vibration sensor TMAC also monitors spindle bearing health, with the analysis initiated by calls in the CNC program. The TMAC data viewer and event log stores all cutting data and events. Any number of data files can be opened simultaneously to easily view graphical differences and allows overlaying cutting data to compare and analyze cuts. “TMAC’s universal interfacing compatibility with any CNC control allows us to not only monitor processes and detect anomalies, but make real-time automatic (corrective) adjustments, without the need for human intervention. This is true of all Caron products,” said Rob Caron, President of Caron Engineering. [Learn More About TMAC 3.0](https://www.caroneng.com/products/tmac/) ## CNC Tool Signature Analysis --- ## [CNC Tool Monitoring: Cutting Signature Analysis](https://www.caroneng.com/signature-analysis) # CNC Tool Monitoring: Cutting Signature Analysis For certain cutting operations, using a fixed limit or work to monitor the condition of a cutting tool is not always the most effective solution. In these instances, the use of signature analysis provides a monitoring approach that accounts for the variable load change on the tool due to a variety of circumstances. The variations could be attributed to a change in RPM, tool path or other factors. Signature analysis is most useful for high precision or repeatable cutting operations where slight variations in tool path can have a large impact on the final product. To perform this, the signature analysis software learns the entire signature (path) of a cut using any [sensor](https://www.caroneng.com/products/tmac/#sensors-and-components) type. The user can define boundaries around the learned signature, both above and below it. These boundaries define a window that the signature must stay within to satisfy a good cut. If any portion of the signature of a monitored tool exceeds the warning (yellow) or extreme (red) boundaries, an alarm is generated. Signature analysis is also another method to monitor tool wear so that we can quickly identify when a tool needs to be replaced. The versatility of Caron Engineering's tool monitoring systems allow monitoring each tool and cutting section with the most appropriate method. This capability provides the user with the ability to switch from monitoring the work of the cutting tool to the signature analysis mode for cutting operations where it is most suitable, such as constant surface speed cuts and part-off operations. ### Constant Surface Speed Cutting Operations The signature analysis monitoring capability can be applied most notably to constant surface speed cutting operations where the material diameter changes consistently during a cut. With diameter changes, the RPM varies as the material increases or decreases causing sensor fluctuations unrelated to the tooling. In manufacturing, this applies to such constant surface speed cutting as facing and turning operations on a CNC lathe, where the RPM is being adjusted automatically to maintain a proper chip load. The lathe starts cutting at the original diameter of the part and as it removes material, the diameter is consistently decreasing. Those RPM changes cause a fluctuation in power which is difficult to monitor with tool load monitoring. By learning the signature of the cut and setting boundaries around the learned signature, these cuts can be accurately monitored to ensure optimal surface finish. ### Deep Part-Off Operations Deep part-off operations can be challenging, and when they go wrong, they go very wrong. At the very least, you’re replacing the part-off blade. Worse yet, you end up friction welding your tool to the stock and potentially need to realign your machine. The most common modes of failure are small fractures in the cutting edges, resulting in increased load on the spindle, or more catastrophic fractures where you lose a significant portion of the insert. In the second scenario, you actually see a dip in power before the broken tool re-engages the material and quickly destroys the tool body. With signature analysis this dip in power is easily detected. By tightly bounding the known (learned) power of the part-off cutting operations with the signature analysis warning and extreme thresholds, the system is able to protect machines from both modes of failure. ## Key Features of Signature Analysis - _Monitors the entire path of a tool in cut_ - _Certifies optimum surface finish of each monitored part_ - _Alarms when any portion of the cut exceeds a user-defined boundary_ - _Identifies when material is missing anywhere in a cut_ - _Ideal for constant surface speed cutting operations_ - _Easily registers a dip in the power to safeguard part-off operations_ ## Products with Signature Analysis Capability Adaptive Tool Monitoring System [LEARN MORE ABOUT TMAC](https://www.caroneng.com/products/tmac/) CNC Sensor Analysis System [LEARN MORE ABOUT DTECT-IT](https://www.caroneng.com/products/dtect-it/) ## Privacy Policy Overview --- ## [Spindle Vibration Monitoring Software](https://www.caroneng.com/bearing-analysis) # Spindle Vibration Monitoring Software \| Bearing Analysis _**Monitor Spindle Health to Avoid Costly Downtime**_ Bad spindle bearings that go undetected can lead to excessive vibration, diminished machining performance, and ultimately, spindle failure. Caron Engineering’s bearing analysis system using spindle vibration monitoring technology provides a proactive approach to spindle health monitoring, identifying when bearings need attention before small issues escalate into costly repairs or unplanned downtime. Our CNC spindle vibration monitoring software seamlessly integrates with a Caron Engineering vibration sensor mounted on the spindle to run the bearing analysis. This advanced sensor captures and analyzes two critical vibration signatures: Acceleration Signature: Evaluates the health and condition of the bearings. Velocity Signature: Detects potential issues like misalignment, imbalance, or looseness in the spindle assembly. ## Vibration Analysis Results The analysis is initiated directly through the CNC part program, ensuring a streamlined process that fits into your existing workflow. Results are delivered within just **five seconds**, providing instant insights to guide maintenance decisions. For traceability and further review, the detailed bearing report is automatically saved as a file. **Real-Time Visual Feedback**![Spindle Bearing Analysis Result_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Spindle-Bearing-Analysis-Result_Caron-Engineering.png) To make results actionable, the HMI screen features a clear **color-coded indicator**: - **Green**: Bearings are in excellent or good condition. - **Yellow**: Bearings require attention. - **Red**: Immediate maintenance is needed. **Historical Data at Your Fingertips** The software’s historical viewer allows users to review previous analyses and monitor trends over time. This capability enables predictive maintenance, helping you schedule servicing based on actual bearing performance rather than relying on arbitrary maintenance intervals. By incorporating Caron Engineering’s spindle monitoring solution, you can ensure maximum spindle life, reduce unscheduled downtime, and maintain optimal machining performance. ### Features of Spindle Bearing Health Monitoring - **Real-Time Vibration Analysis**: Monitors acceleration and velocity signatures to assess bearing health and detect misalignment, imbalance, or looseness. - **Automated CNC Integration**: Initiates analysis directly from the CNC part program with results displayed within seconds. - **Color-Coded HMI Feedback**: Visual indicators (green, yellow, red) for immediate assessment of bearing condition. - **Data Logging**: Saves detailed bearing reports for traceability and in-depth review. - **Historical Trend Viewer**: Tracks bearing performance over time for predictive maintenance. ### Benefits of Spindle Bearing Health Monitoring - **Prevents Unplanned Spindle Failures**: Detects issues early to avoid costly repairs and downtime. - **Optimizes Maintenance Scheduling**: Enables predictive maintenance based on real data, reducing unnecessary servicing. - **Reduces Costs**: Minimizes unplanned maintenance expenses. - **Streamlines Operations**: Integrates seamlessly into CNC workflows for efficiency and ease of use. ## Products with Bearing Analysis Capability Adaptive Tool Monitoring System [LEARN MORE ABOUT TMAC](https://www.caroneng.com/products/tmac/) CNC Sensor Analysis System [LEARN MORE ABOUT DTect-IT](https://www.caroneng.com/products/dtect-it/) ## RFID Operator Authentication --- ## [RFID Operator Authentication for CNC Machining](https://www.caroneng.com/rfid-operator-authentication) # RFID Operator Authentication for CNC Machining When it comes to machine and manufacturing software access, accountability of interactions and permissions is growing increasingly more important to monitor with the decrease of skilled labor and increase in employee turnover. Currently, most manufacturing systems and software are accessed by use of physical keys or passwords, all of which can be shared without traceability. ## RFID Badge Access System Using [ELATEC Inc.](https://www.linkedin.com/company/elatec-usa-inc./) RFID badge readers integrated with our MiConnect Technology solution to interface with the CNC, we can control user access to manufacturing systems, both physical and software, directly from the employee badge. [MiConnect Technology](https://www.caroneng.com/miconnect-technology/) is a customizable application builder for the CNC manufacturing environment that allows us to easily integrate devices and operations on a shop floor to automate processes. Using a database of user credentials and access levels, we can use MiConnect Technology to connect the user permissions to each employee badge to allow access via a simple RFID badge scan at the machine or application. [RFID User Authentication: Enhancing Manufacturing Security \| Caron Engineering](https://www.youtube.com/watch?v=l_lVU70P0F0) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=l_lVU70P0F0) Check out this video to see how our RFID User Authentication System can safeguard access to all your manufacturing systems. ## No More Keys or Passwords Because the machine access is integrated with the employee ID badge, it alleviates the need to carry an additional access card, keys, or remember passwords. The system can be configured to grant access to specific machines or entire manufacturing lines, with individualized access to programs, screens, and application functions based on the user’s role. This eliminates the risk of unauthorized use and helps prevent unscheduled downtime when inexperienced users have unmonitored system access. The data is maintained in a centralized location, so when employee turnover occurs, all access can be remotely removed from the badge database alleviating any issues with collecting physical assets (keys) upon exit. If the employee role changes, this can easily be updated at any time. ## Fully Traceable MiConnect Technology applications have an inherent audit log that tracks every interaction with date and time stamp. This helps provide a clear audit trail of who accessed what equipment, when they accessed it, and how long they were using the equipment. Users will be discouraged from sharing their employee badge for any system access knowing there is full accountability of their interactions. The logs and reports can all be customized to easily display the information you need at a glance. ## Safeguard Physical Systems Access Starting a CNC machine that is not ready to be run can be catastrophic. Currently, there is nothing safeguarding the machine that prevents just anyone from pushing the start button. Using the RFID badge reader system, we can require authorization to activate the machine cycle start. Similarly, a physical key is required to access the NC control panel to make part program edits and enter maintenance codes. Losing and sharing keys is a constant concern when it comes to safeguarding who can access the CNC control panel. With an authorized RFID badge scan, MiConnect can take over the physical key turn function to access the panel. This ensures only authorized users are accessing these functions and provides complete traceability of each scanned interaction. _Flow chart shows how inputs and outputs tied to machine IO allow MiConnect to take over the normal physical functions of a key turn or a button press. MiConnect can also communicate user access via ethernet commands to the system._ ## Integrates with Caron Engineering Products The access can also apply to all Caron Engineering products and software. For instance, our adaptive tool monitoring system, [TMAC](https://www.caroneng.com/products/tmac/), has system securities that allow customized access within the software based on the user role. Using MiConnect technology, we can connect these unique access permissions to the employee RFID badge. **The RFID Badge Reader System Provides** - Customized access to all manufacturing systems via RFID badge scan - Systemized securities to safeguard machines and control processes - Full tracking and accountability of every scan and action - Remote access to update user credentials and permissions - No more keys and passwords! [Contact Us to Learn More](https://www.caroneng.com/contact/ "Contact Us to Learn More") [![Elatec Case Study_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Elatec-Case-Study_Caron-Engineering.jpg)](https://www.caroneng.com/wp-content/uploads/Caron-Engineering-Machine-Operator-Authentication-case-study.pdf) ## Related Products ### Streamlined Process Automation Software ### Adaptive Tool Monitoring System ### RFID Tool Data Management System ## Caron Engineering About Page --- ## [About Caron Engineering](https://www.caroneng.com/about) # About Caron Engineering At Caron Engineering, our mission is to transcend industry standards by developing cutting-edge tool monitoring, automation, and process control technologies that optimize performance, boost productivity, and maximize profitability for the manufacturing sector. Since our founding in 1986, we have been at the forefront of smart manufacturing innovation. Our advanced solutions are utilized worldwide and integrate seamlessly with virtually any CNC machine tool, regardless of the builder. Leveraging high-precision sensors and high-speed data processing, our products enable real-time automated adjustments, optimize machining processes, and deliver critical insights into cutting performance and machine health. All our systems are equipped with custom drivers to ensure effortless communication with production monitoring platforms and supervisory systems. We are dedicated to delivering smart manufacturing solutions that reduce cycle times, streamline automation, enable unattended operations, minimize tooling costs, and prevent costly machine and work-holding damage. Guided by our commitment to “Adaptive Solutions for the Future of Manufacturing,” we combine strong leadership, innovation, and determination to empower our customers. At Caron Engineering, innovation is what drives us. Download the Company Brochure # An Employee Owned Company As an employee-owned entity (ESOP), we embrace our ownership culture to create a team of highly motivated individuals who are dedicated to serving customers and the community. We believe that employee engagement is one of the keys to our success, and we work hard to provide an environment where every employee feels valued, respected, and rewarded for their contributions. This is an essential part of our success in bringing the best possible service and quality to our customers. ## Learn More ### Production Technology Center – TX ### Technology Partners ### Clients and Industries ## Adaptive Control in Machining --- ## [Real-Time Adaptive Control: The Key to Faster, More Stable CNC Machining](https://www.caroneng.com/real-time-adaptive-control-the-key-to-faster-more-stable-machining) # Real-Time Adaptive Control: The Key to Faster, More Stable CNC Machining Automation isn’t just about robots and conveyors—it’s about making smarter decisions automatically during the machining process. While many manufacturers have embraced automation for part handling or data feedback, one of the most overlooked opportunities is in-process cutting optimization. This is where adaptive control makes the difference. If you’re running complex geometries, machining expensive alloys, or producing high-value components where integrity is non-negotiable, you already know that cutting conditions rarely remain constant. Even within a single cycle, variables shift, tool wear accumulates, material hardness varies, and chips pack unexpectedly. These subtle changes can lead to inefficient machining, broken tools, extended cycle times, or worse—scrapped parts that took hours to produce. **Adaptive control addresses this problem at its source: the cut itself.** ## What is Adaptive Control in CNC Machining? Adaptive control is a real-time, closed-loop feedback system that adjusts the machine’s cutting parameters based on what is actually happening during the cut—not just what was programmed. Traditional CNC programs are written with conservative assumptions. Programmers must account for worst-case scenarios to protect tools and parts. The result? Machines often run slower than they need to. Adaptive control removes that limitation. At Caron Engineering, we deliver this capability with [**TMAC (Tool Monitoring Adaptive Control)**.](https://www.caroneng.com/products/tmac/) TMAC continuously measures the true spindle power load during machining, analyzing cutting data thousands of times per second. TMAC learns the optimal power profile for each tool and cutting segment, continuously comparing it against user-defined limits to calculate tool wear in real time during the cut. [Real-Time Adaptive Control with TMAC on FANUC Robodrill](https://www.youtube.com/watch?v=K64yRb6-AQ0) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=K64yRb6-AQ0) When cutting conditions are favorable—such as air cuts, light radial engagement, or clean material sections— **TMAC adaptive control automatically _increases_ the feed rate to optimize cutting and reduce cycle time.** When the load rises due to tool wear, material variation, or depth of cut, TMAC instantly **_reduces_ the feed rate to maintain a constant spindle motor power, to extend tool life and protect the cutting process.** In the event there is an extreme spike in cutting load, TMAC stops the machine entirely to protect the tool and part. It’s like giving your CNC machine a built-in sense of feel—allowing it to react intelligently and automatically to real-world cutting conditions. ## Why Adaptive Feed Rate Control Matters _Without_ adaptive control, you’re forced to choose between productivity and protection. Program too aggressively, and you risk tool breakage. Program too conservatively, and you sacrifice throughput. **Adaptive control eliminates that compromise** by dynamically optimizing feed rates in real time. #### The Results are Measurable - **Reduced cycle times** by increasing feeds during lighter cutting conditions - **Extended tool life** by minimizing unnecessary overload during heavy engagement - **Prevention of catastrophic tool breakage** through instantaneous load detection - **Improved surface finish and dimensional stability** through stabilized cutting forces Because TMAC logs all cutting data, manufacturers also gain traceability and process insight that can be used to refine programs, optimize tooling strategies, and validate machining performance across shifts or facilities. [Reduce Cycle Time with Adaptive Control](https://www.caroneng.com/products/tmac/#adaptive-control-feed-rate-optimization1) ## High-Value Parts Demand Intelligent Control In industries such as aerospace, medical device manufacturing, energy, and defense, machining is not just about speed—it’s about integrity. High-value components often involve: - **Difficult-to-machine materials like titanium or Inconel** - **Long cycle times with deep cavity work** - **Tight tolerances requiring process consistency** - **Expensive raw material costs** - **Strict quality and traceability requirements** In these environments, a single tool failure can destroy hours of machining time and thousands of dollars in material. Worse yet, subtle tool wear that goes undetected can compromise part integrity without immediate visibility. Adaptive control adds a layer of protection that manual oversight simply cannot match. It continuously monitors tool load signatures, detecting both gradual wear trends and sudden anomalies. That means tools are replaced predictably—based on actual cutting behavior—not guesswork. For high-value manufacturing, this level of process awareness isn’t optional. It’s foundational. ## Integrating Adaptive Control Into Your Process One of the most powerful aspects of TMAC is that it does not require rewriting CNC programs or replacing legacy equipment. **TMAC integrates directly with your existing CNC controls** and can be configured for individual tools, specific operations, or defined cutting segments within a program. It adapts to your process—not the other way around. Whether you are: - Running 5-axis contouring - Performing heavy roughing in hardened steel - Machining long-run aerospace structural parts - Or pushing cycle times in high-volume production Adaptive control can be implemented incrementally and scaled as needed. [TMAC Adaptive Feed Rate Control Demonstration on an Okuma Genos M560-V](https://www.youtube.com/watch?v=VfSHb6Nq8iA) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=VfSHb6Nq8iA) ## Smarter, Faster, Safer Machining—Automatically With adaptive control in place, machines no longer operate blindly. They respond. They **accelerate** when possible. They **protect** themselves when necessary. They **extend tool life based** on actual performance data. They **maintain consistency** across material batches and shifts. Instead of reacting to failures, manufacturers gain confidence that their machining process is actively optimizing itself in real time. You stop leaving productivity on the table—and you stop accepting unnecessary risk. ## FAQs - Adaptive Feed Rate Automation What is adaptive control in CNC machining and how does it work? Adaptive control in CNC machining is a real-time system that automatically adjusts cutting parameters based on actual conditions during the cut. Instead of relying on fixed programming, it monitors spindle load and reacts instantly to changes in tool wear, material variation, or engagement. Caron Engineering’s [TMAC adaptive control system](https://www.caroneng.com/products/tmac/) measures cutting load thousands of times per second and dynamically adjusts feed rates to match real cutting conditions. This allows CNC machines to run at optimal performance while maintaining process stability and part quality. How does TMAC adaptive control reduce cycle time without increasing risk? Caron Engineering’s TMAC increases feed rates during light cutting conditions such as air cuts or low engagement, where traditional programs run conservatively. This reduces cycle time without introducing instability into the process. When cutting loads increase, TMAC automatically reduces feed or intervenes to protect the tool and part. This balance allows manufacturers to improve throughput while maintaining control over cutting forces and process reliability. How does TMAC prevent tool breakage and protect high-value parts? TMAC continuously monitors cutting (power) load and detects abnormal conditions caused by tool wear, chip buildup, or unexpected cutting conditions, and will stop the machine within 5 milliseconds of detecting an extreme event. This real-time protection helps prevent catastrophic tool failure, protects expensive workpieces, and reduces unplanned downtime. It is especially valuable in long-cycle, high-value machining where a single failure can result in significant material loss. Can TMAC adaptive control be integrated into existing CNC machines? Yes. Caron Engineering’s TMAC integrates directly with existing CNC controls and does not require rewriting programs or replacing equipment. This allows manufacturers to introduce adaptive control into legacy environments, scale implementation over time, and improve performance without disrupting existing workflows. Adaptive control can be applied to individual cuts monitored by TMAC where the automated feed rate adjustment is most beneficial, especially with long cycles and removing significant amounts of material. - > Adaptive control isn’t a new concept—it’s proven technology that continues to evolve with modern manufacturing demands. At Caron Engineering, adaptive control has been embedded into our tool monitoring systems since the 1990s, long before Industry 4.0 became a buzzword. By combining real-time sensing with closed-loop control, we’ve continuously refined how machines respond to cutting conditions—optimizing performance, extending tool life, and protecting every cycle. It’s this legacy of innovation that allows manufacturers today to move toward truly intelligent machining. - > Adaptive control isn’t a new concept—it’s proven technology that continues to evolve with modern manufacturing demands. At Caron Engineering, adaptive control has been embedded into our tool monitoring systems since the 1990s, long before Industry 4.0 became a buzzword. By combining real-time sensing with closed-loop control, we’ve continuously refined how machines respond to cutting conditions—optimizing performance, extending tool life, and protecting every cycle. It’s this legacy of innovation that allows manufacturers today to move toward truly intelligent machining. - > Adaptive control isn’t a new concept—it’s proven technology that continues to evolve with modern manufacturing demands. At Caron Engineering, adaptive control has been embedded into our tool monitoring systems since the 1990s, long before Industry 4.0 became a buzzword. By combining real-time sensing with closed-loop control, we’ve continuously refined how machines respond to cutting conditions—optimizing performance, extending tool life, and protecting every cycle. It’s this legacy of innovation that allows manufacturers today to move toward truly intelligent machining. [Contact Our Team](https://www.caroneng.com/contact/) ## Related Technology for CNC Machining ### Adaptive Tool Monitoring System ### Automated CNC Offset Control Software ### Low Code CNC Automation Platform ## Manufacturing Automation Results --- ## [Case Studies](https://www.caroneng.com/results) # Case Studies \| Machine Shop Automation Systems See how our customers are benefiting from integrating our manufacturing solutions! - All ProductsAutoCompDTect-ITMiConnectTMACToolConnect [![12353 Thumbnail_Caron Engineering](https://www.caroneng.com/wp-content/uploads/12353-Thumbnail.png)](https://www.caroneng.com/result/tmac-detects-material-defect-mid-cut-preventing-tool-damage-and-protecting-part-quality/) ## [TMAC Detects Material Defect Mid-Cut—Preventing Tool Damage and Protecting Part Quality](https://www.caroneng.com/result/tmac-detects-material-defect-mid-cut-preventing-tool-damage-and-protecting-part-quality/ "TMAC Detects Material Defect Mid-Cut—Preventing Tool Damage and Protecting Part Quality") [See the Results](https://www.caroneng.com/result/tmac-detects-material-defect-mid-cut-preventing-tool-damage-and-protecting-part-quality/ "See the Results") [![78754_Thumbnail](https://www.caroneng.com/wp-content/uploads/78754_Thumbnail.png)](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/) ## [From Notification to Protection: Automating Chip Overflow Prevention with MiConnect](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/ "From Notification to Protection: Automating Chip Overflow Prevention with MiConnect") [See the Results](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/ "See the Results") [![12121 Thumbnail with Logo](https://www.caroneng.com/wp-content/uploads/12121-Thumbnail.png)](https://www.caroneng.com/result/tmac-optimizes-grinding-efficiency-and-prevents-costly-spindle-failure-in-aerospace-manufacturing-2/) ## [TMAC Optimizes Grinding Efficiency and Prevents Costly Spindle Failure in Aerospace Manufacturing](https://www.caroneng.com/result/tmac-optimizes-grinding-efficiency-and-prevents-costly-spindle-failure-in-aerospace-manufacturing-2/ "TMAC Optimizes Grinding Efficiency and Prevents Costly Spindle Failure in Aerospace Manufacturing") [See the Results](https://www.caroneng.com/result/tmac-optimizes-grinding-efficiency-and-prevents-costly-spindle-failure-in-aerospace-manufacturing-2/ "See the Results") [![TMACai Thumbnail 12781](https://www.caroneng.com/wp-content/uploads/TMACai-thumbnail.png)](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/) ## [TMAC AI Empowers Predictive Quality and Root-Cause Intelligence for Precision Manufacturing](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/ "TMAC AI Empowers Predictive Quality and Root-Cause Intelligence for Precision Manufacturing") [See the Results](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/ "See the Results") [![12445 Thumbnail_Caron Engineering](https://www.caroneng.com/wp-content/uploads/12445-Thumbnail.png)](https://www.caroneng.com/result/tool-monitoring-recovers-lights-out-operation/) ## [Tool Monitoring Recovers Lights Out Operation for Brass Parts Manufacturer](https://www.caroneng.com/result/tool-monitoring-recovers-lights-out-operation/ "Tool Monitoring Recovers Lights Out Operation for Brass Parts Manufacturer") [See the Results](https://www.caroneng.com/result/tool-monitoring-recovers-lights-out-operation/ "See the Results") [![MiConnect 10928 Thumbnail](https://www.caroneng.com/wp-content/uploads/MiConnect-10928-Thumbnail.png)](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/) ## [MiConnect Technology Powers Automation for this Medical Device Manufacturer](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/ "MiConnect Technology Powers Automation for this Medical Device Manufacturer") [See the Results](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/ "See the Results") [![](https://www.caroneng.com/wp-content/uploads/9618-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/machine-runout-detection-case-study/) ## [Machining Runout Detection Eliminates Scrap Caused by Chip Interference](https://www.caroneng.com/result/machine-runout-detection-case-study/ "Machining Runout Detection Eliminates Scrap Caused by Chip Interference") [See the Results](https://www.caroneng.com/result/machine-runout-detection-case-study/ "See the Results") [![](https://www.caroneng.com/wp-content/uploads/10203-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/cnc-tool-management-system/) ## [Tool Data Management System Eliminates Costly Errors Machining Pistol Barrels](https://www.caroneng.com/result/cnc-tool-management-system/ "Tool Data Management System Eliminates Costly Errors Machining Pistol Barrels") [See the Results](https://www.caroneng.com/result/cnc-tool-management-system/ "See the Results") [![TMAC Cuts Scrap Rate by Monitoring and Detecting Breakage on a .030" Drill](https://www.caroneng.com/wp-content/uploads/9930-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/tmac-cuts-scrap-rate-by-monitoring-and-detecting-breakage-on-a-030-drill/) ## [TMAC Cuts Scrap Rate by Monitoring and Detecting Breakage on a .030″ Drill](https://www.caroneng.com/result/tmac-cuts-scrap-rate-by-monitoring-and-detecting-breakage-on-a-030-drill/ "TMAC Cuts Scrap Rate by Monitoring and Detecting Breakage on a .030″ Drill") [See the Results](https://www.caroneng.com/result/tmac-cuts-scrap-rate-by-monitoring-and-detecting-breakage-on-a-030-drill/ "See the Results") [![Process Time Reduced by 92% Using DTect-IT Surface Scanning Application](https://www.caroneng.com/wp-content/uploads/9909-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/process-time-reduced-by-92-using-dtect-it-surface-scanning-application/) ## [Process Time Reduced by 92% Using DTect-IT Surface Scanning Application](https://www.caroneng.com/result/process-time-reduced-by-92-using-dtect-it-surface-scanning-application/ "Process Time Reduced by 92% Using DTect-IT Surface Scanning Application") [See the Results](https://www.caroneng.com/result/process-time-reduced-by-92-using-dtect-it-surface-scanning-application/ "See the Results") [![Tool Health Check DTect-IT](https://www.caroneng.com/wp-content/uploads/9636-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/tmac-cuts-tooling-costs-by-72-with-real-time-tool-breakage-detection/) ## [Tool Breakage Detection \| TMAC Reduces Tooling Costs by 72% with Real-Time Monitoring](https://www.caroneng.com/result/tmac-cuts-tooling-costs-by-72-with-real-time-tool-breakage-detection/ "Tool Breakage Detection | TMAC Reduces Tooling Costs by 72% with Real-Time Monitoring") [See the Results](https://www.caroneng.com/result/tmac-cuts-tooling-costs-by-72-with-real-time-tool-breakage-detection/ "See the Results") [![9209 Thumbnail with Logo_2](https://www.caroneng.com/wp-content/uploads/9209-Thumbnail-with-Logo_2.png)](https://www.caroneng.com/result/dtect-it-maintains-part-accuracy-with-very-tight-tolerances/) ## [DTect-IT Maintains Part Accuracy with Very Tight Tolerances](https://www.caroneng.com/result/dtect-it-maintains-part-accuracy-with-very-tight-tolerances/ "DTect-IT Maintains Part Accuracy with Very Tight Tolerances") [See the Results](https://www.caroneng.com/result/dtect-it-maintains-part-accuracy-with-very-tight-tolerances/ "See the Results") [![](https://www.caroneng.com/wp-content/uploads/9153-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/toolconnect-eliminates-errors-loading-cnc-tools/) ## [ToolConnect Simplifies CNC Tool Loading and Reduces Errors](https://www.caroneng.com/result/toolconnect-eliminates-errors-loading-cnc-tools/ "ToolConnect Simplifies CNC Tool Loading and Reduces Errors") [See the Results](https://www.caroneng.com/result/toolconnect-eliminates-errors-loading-cnc-tools/ "See the Results") [![ToolConnect Prevents CNC Data Entry Errors and Downtime](https://www.caroneng.com/wp-content/uploads/ToolConnect-Prevents-CNC-Thumbnail.png)](https://www.caroneng.com/result/toolconnect-eliminates-costly-downtime-due-to-human-data-entry-errors/) ## [ToolConnect Prevents CNC Data Entry Errors and Downtime](https://www.caroneng.com/result/toolconnect-eliminates-costly-downtime-due-to-human-data-entry-errors/ "ToolConnect Prevents CNC Data Entry Errors and Downtime") [See the Results](https://www.caroneng.com/result/toolconnect-eliminates-costly-downtime-due-to-human-data-entry-errors/ "See the Results") [![Spindle Vibration Monitoring Reduces Scrap from Bar Stock Defects](https://www.caroneng.com/wp-content/uploads/Spindle-Monitoring-Thumbnail.png)](https://www.caroneng.com/result/spindle-vibration-monitoring-reduces-scrap-from-bar-stock-defects/) ## [Spindle Vibration Monitoring Reduces Scrap from Bar Stock Defects](https://www.caroneng.com/result/spindle-vibration-monitoring-reduces-scrap-from-bar-stock-defects/ "Spindle Vibration Monitoring Reduces Scrap from Bar Stock Defects") [See the Results](https://www.caroneng.com/result/spindle-vibration-monitoring-reduces-scrap-from-bar-stock-defects/ "See the Results") [![Tool Monitoring Increases Productivity with 24/7 Lights- Out Machining](https://www.caroneng.com/wp-content/uploads/6666-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/tool-monitoring-enhances-lights-out-cnc-productivity/) ## [Tool Monitoring Increases Productivity with 24/7 Lights-Out Machining](https://www.caroneng.com/result/tool-monitoring-enhances-lights-out-cnc-productivity/ "Tool Monitoring Increases Productivity with 24/7 Lights-Out Machining") [See the Results](https://www.caroneng.com/result/tool-monitoring-enhances-lights-out-cnc-productivity/ "See the Results") [![Customer Reduces Cycle Time by 41% Using TMAC Adaptive Control Feed Rate Optimization](https://www.caroneng.com/wp-content/uploads/6120-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/customer-reduces-cycle-time-by-41-using-tmac-adaptive-control-feed-rate-optimization/) ## [Manufacturer Cuts Cycle Time by 41% with TMAC’s Adaptive Feed Rate Control](https://www.caroneng.com/result/customer-reduces-cycle-time-by-41-using-tmac-adaptive-control-feed-rate-optimization/ "Manufacturer Cuts Cycle Time by 41% with TMAC’s Adaptive Feed Rate Control") [See the Results](https://www.caroneng.com/result/customer-reduces-cycle-time-by-41-using-tmac-adaptive-control-feed-rate-optimization/ "See the Results") [![Aluminum Hydraulic Manifold Machined 24% Faster Using TMAC Optimization](https://www.caroneng.com/wp-content/uploads/Aluminum-Hydraulic-Manifold-Thumbnail.png)](https://www.caroneng.com/result/tmac-reduces-cycle-time-by-24-machining-an-aluminum-hydraulic-manifold/) ## [Aluminum Hydraulic Manifold Machined 24% Faster Using TMAC Optimization](https://www.caroneng.com/result/tmac-reduces-cycle-time-by-24-machining-an-aluminum-hydraulic-manifold/ "Aluminum Hydraulic Manifold Machined 24% Faster Using TMAC Optimization") [See the Results](https://www.caroneng.com/result/tmac-reduces-cycle-time-by-24-machining-an-aluminum-hydraulic-manifold/ "See the Results") [![TMAC Prevents Tool Failure and Boosts Efficiency on High-Value $150K Part](https://www.caroneng.com/wp-content/uploads/TMAC-Prevents-Tool-Failure-Thumbnail.png)](https://www.caroneng.com/result/tmac-reduces-cycle-time-and-prevents-tool-breakage-on-a-150k-part/) ## [TMAC Prevents Tool Failure and Boosts Efficiency on High-Value $150K Part](https://www.caroneng.com/result/tmac-reduces-cycle-time-and-prevents-tool-breakage-on-a-150k-part/ "TMAC Prevents Tool Failure and Boosts Efficiency on High-Value $150K Part") [See the Results](https://www.caroneng.com/result/tmac-reduces-cycle-time-and-prevents-tool-breakage-on-a-150k-part/ "See the Results") [![Automated Tool Wear Compensation Software Contributes to Unmanned Operations](https://www.caroneng.com/wp-content/uploads/5369-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/automated-tool-wear-compensation-software-contributes-to-unmanned-operations/) ## [Automated Offset Adjustments Contribute to Unmanned Operations](https://www.caroneng.com/result/automated-tool-wear-compensation-software-contributes-to-unmanned-operations/ "Automated Offset Adjustments Contribute to Unmanned Operations") [See the Results](https://www.caroneng.com/result/automated-tool-wear-compensation-software-contributes-to-unmanned-operations/ "See the Results") [![TMAC Saves $300K per Month for this Automotive Customer Machining Camshafts](https://www.caroneng.com/wp-content/uploads/3674-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/tmac-saves-300k-per-month-for-this-automotive-customer-machining-camshafts/) ## [TMAC Saves $300K per Month for this Automotive Customer Machining Camshafts](https://www.caroneng.com/result/tmac-saves-300k-per-month-for-this-automotive-customer-machining-camshafts/ "TMAC Saves $300K per Month for this Automotive Customer Machining Camshafts") [See the Results](https://www.caroneng.com/result/tmac-saves-300k-per-month-for-this-automotive-customer-machining-camshafts/ "See the Results") [![TMAC Prevents a Costly Crash by Stopping this Extreme Condition in its Tracks](https://www.caroneng.com/wp-content/uploads/7166-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/tmac-prevents-a-costly-crash-by-stopping-this-extreme-condition-in-its-tracks/) ## [TMAC Prevents a Costly Crash by Stopping this Extreme Condition in its Tracks](https://www.caroneng.com/result/tmac-prevents-a-costly-crash-by-stopping-this-extreme-condition-in-its-tracks/ "TMAC Prevents a Costly Crash by Stopping this Extreme Condition in its Tracks") [See the Results](https://www.caroneng.com/result/tmac-prevents-a-costly-crash-by-stopping-this-extreme-condition-in-its-tracks/ "See the Results") [![](https://www.caroneng.com/wp-content/uploads/10165-Thumbnail-with-Logo_1-1.png)](https://www.caroneng.com/result/real-time-tool-wear-monitoring-eliminates-downtime-and-cuts-tooling-costs-by-50/) ## [Real Time Tool Monitoring Eliminates Downtime and Cuts Tooling Cost by 50%](https://www.caroneng.com/result/real-time-tool-wear-monitoring-eliminates-downtime-and-cuts-tooling-costs-by-50/ "Real Time Tool Monitoring Eliminates Downtime and Cuts Tooling Cost by 50%") [See the Results](https://www.caroneng.com/result/real-time-tool-wear-monitoring-eliminates-downtime-and-cuts-tooling-costs-by-50/ "See the Results") [![DTect-IT Monitors Tool Wear and Breakage of a 2.7mm Drill and 3.05mm Reamer](https://www.caroneng.com/wp-content/uploads/9111-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/dtect-it-monitors-tool-wear-and-breakage-of-a-2-7mm-drill-and-3-05mm-reamer/) ## [DTect-IT Monitors Tool Wear and Breakage of a 2.7mm Drill and 3.05mm Reamer](https://www.caroneng.com/result/dtect-it-monitors-tool-wear-and-breakage-of-a-2-7mm-drill-and-3-05mm-reamer/ "DTect-IT Monitors Tool Wear and Breakage of a 2.7mm Drill and 3.05mm Reamer") [See the Results](https://www.caroneng.com/result/dtect-it-monitors-tool-wear-and-breakage-of-a-2-7mm-drill-and-3-05mm-reamer/ "See the Results") [![In-Process Inspection Plays a Key Roll in Productivity Increases for this Customer](https://www.caroneng.com/wp-content/uploads/4899-Thumbnail-with-Logo_1.png)](https://www.caroneng.com/result/in-process-inspection-plays-a-key-roll-in-productivity-increases-for-this-customer/) ## [In-Process Inspection Plays a Key Roll in Productivity Increases for this Customer](https://www.caroneng.com/result/in-process-inspection-plays-a-key-roll-in-productivity-increases-for-this-customer/ "In-Process Inspection Plays a Key Roll in Productivity Increases for this Customer") [See the Results](https://www.caroneng.com/result/in-process-inspection-plays-a-key-roll-in-productivity-increases-for-this-customer/ "See the Results") These case studies highlight how the implementation of Caron Engineering's smart technology systems result in a substantial increase in productivity and profitability. Through automation and process control features, tasks that previously required manual intervention can now be performed autonomously, allowing operators to focus on higher-value activities. With precise tool monitoring, potential issues can be detected and addressed proactively, ensuring maximized tool life and minimizing unexpected downtime due to tool failure or wear. By extending tool life and minimizing scrap, manufacturers can achieve better resource utilization and higher yields, further bolstering the bottom line. In essence, the adoption of Caron Engineering's smart technology solutions not only automate and optimize manufacturing processes but also enhance overall performance, positioning companies for sustained success in today's competitive landscape. ## Manufacturing Optimization Solutions --- ## [Tool Data Management System Eliminates Costly Errors Machining Pistol Barrels](https://www.caroneng.com/result/cnc-tool-management-system) # Tool Data Management System Eliminates Costly Errors Machining Pistol Barrels | | | | --- | --- | | **Industry:** | Firearms Manufacturing | | **Machine:** | Machining Center | | **Tooling:** | End Mill | [![](https://www.caroneng.com/wp-content/uploads/Tool-Connect-Color-match-768x238.png)](https://www.caroneng.com/products/toolconnect/) ## Challenge A customer machining high-volume firearm parts noticed a bad surface finish on their pistol barrel component. After further inspection of the part, it was determined that the last 6 pistol barrels also had a poor surface finish. The result and disposition after a quality review was that those 6 parts were not recoverable and ultimately needed to be scrapped. ## Solution The customer needed a solution to regulate this process and implemented Caron Engineering’s [ToolConnect](https://www.caroneng.com/products/toolconnect/), RFID Tool Data Management System. ToolConnect allows this customer to use a tool presetter to set-up tools outside of the machine. The presetter records the tool offset data and stores this data on an RFID chip inside the tool holder. When the tool is transferred to the machining center for loading, the tool is placed into an RFID read station and Caron Engineering’s ToolConnect System automatically loads the data to the control offset table. This process workflow eliminates operator errors commonly caused by mis-entering data, saving significant time and money. ToolConnect validates the tool length being loaded into the machine. In this case, where the tool was longer than it should have been due to a measurement error, ToolConnect would have prevented the tool from being registered in the machine and forced the operator to intervene. In this one simple instance, this error resulted in a loss of over $4,000 very quickly. In addition to the scrapped parts, by having the machine down for over 4 hours of troubleshooting, the customer was losing the revenue typically generated by continuously making chips. With [ToolConnect](https://www.caroneng.com/products/toolconnect/) implemented, the customer has eliminated costly errors associated with manual data input and they have reduced setup and cycle time by automating the tool load process and using offline tool measurement. ### Results - Eliminated costly scrap and machine downtime - Automated and error-proofed the tool load process ToolConnect HMI and RFID Read Station [More About Product](https://www.caroneng.com/products/toolconnect/) [See More Results](https://www.caroneng.com/results/?_sft_product=toolconnect) [Download](https://www.caroneng.com/wp-content/uploads/10203_Tool-Data-Management-System-Eliminates-Costly-Errors-Machining-Pistol-Barrels_Caron-Engineering.pdf) ## TMAC Scrap Reduction --- ## [TMAC Cuts Scrap Rate by Monitoring and Detecting Breakage on a .030″ Drill](https://www.caroneng.com/result/tmac-cuts-scrap-rate-by-monitoring-and-detecting-breakage-on-a-030-drill) # TMAC Cuts Scrap Rate by Monitoring and Detecting Breakage on a .030″ Drill | | | | --- | --- | | **Industry:** | Medical | | **Machine:** | Swiss-Style Lathe | | **Material:** | Titanium | | **Tooling:** | 0.030" Twist Drill | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge The end user was using a Swiss-style automatic lathe CNC to drill many super small .030” holes. Their intention was to run a continuous process with unattended (lights-out) operations. Due to the hardness of the titanium part and the smallness of the tool, drills would often break unnoticed, and subsequent parts would be “completed” with missing holes until noticed by a human operator many hours later. This caused an unacceptable scrap rate. ## Solution Caron Engineering installed a [TMAC](https://www.caroneng.com/products/tmac/) system with three PT800 power sensors to measure the power load used by the main spindle, power used by the 0.030” drill spindle and one for the 0.055” drill spindle. Based on learned limits, TMAC was able to determine when the tool was not cutting but should have been (i.e., broken). To do this, TMAC compares the learned cutting power to the user defined limits to detect when too much or not enough power is achieved. When the limit is exceeded, [TMAC](https://www.caroneng.com/products/tmac/) alarms and immediately stops the process within 5 milliseconds, and retracts the tooling. At a glance the operator can determine which tool was broken, replace that broken tool, and restart the process. This gave the customer the ability to run the machine with little to no supervision, while producing very little scrap. ### Results - Reduced scrap and decreased cycle time - Allowed the process to run with little to no operator supervision TMAC Data Viewer – shows successfully drilled holes with the last one generating an extreme alarm indicating tool breakage [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/9930_TMAC-Cuts-Scrap-Rate-by-Monitoring-and-Detecting-Breakage-on-a-.030-Drill.pdf) ## Process Time Reduction --- ## [Process Time Reduced by 92% Using DTect-IT Surface Scanning Application](https://www.caroneng.com/result/process-time-reduced-by-92-using-dtect-it-surface-scanning-application) # Process Time Reduced by 92% Using DTect-IT Surface Scanning Application | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | 5 Axis VMC | | **Material:** | Steel | | **Tooling:** | Chamfer | [![](https://www.caroneng.com/wp-content/uploads/DTect-IT-Logo-768x192.png)](https://www.caroneng.com/products/dtect-it/) ## Challenge This Aerospace customer was manufacturing turbine blades with a very complex profile. The surface profile on each blade needed to be measured precisely in order for a very small chamfer tool to finish the blade. They were using a part probe with standard probing cycles, which required lots of probing points to compensate for any deviations from the process. This process took an average of 3 hours just to collect all the probing points. Next, the compensation data was printed on paper for visual inspection by the CNC operator, to identify any tolerance issues or errors during probing. If/when an error was found, the entire probing process had to be restarted after the suspect surface had been cleaned or repaired. ## Solution Instead of collecting individual probing points, the goal was to scan along each surface of the blade in one continuous motion and store the comprehensive scan data. By implementing [DTect-IT](https://www.caroneng.com/products/dtect-it/) from Caron Engineering, combined with a [Blum Digilog Scanning probe](https://www.caroneng.com/products/blum-novotest/), the customer can scan the edge of the turbine blade and collect datapoints every 1 msec. The probe is linearized, and the deflection output is converted to dimensional data. The XYZ coordinate data is interpolated from the deflection of the touch probe, the feed-rate from the scan, and the vector of the surface. The data output is read by [DTect-IT](https://www.caroneng.com/products/dtect-it/) software and axis adjustments are written to a new subroutine that accounts for the deviations. This subroutine is then called by the main program to automatically adjust the cutter path to correct the chamfer for any aberrations. This entire routine took 16 minutes to complete, saving 164 minutes of process time. Additionally, a backup file is saved, per blade, so the customer can track the data for future analysis, if needed. ### Results - Reduced cycle time for the chamfering preparation by 92% per blade (180 minutes reduced to 16 minutes) - Eliminated operator error review time by 100% - Stored data can be used for future analysis DTect-IT History Viewer shows the details of the surface scan. Click on any point of the scan to view the data. [More About Product](https://www.caroneng.com/products/dtect-it/) [See More Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [Download](https://www.caroneng.com/wp-content/uploads/9909_Process-Time-Reduced-by-92-Using-DTect-IT-Surface-Scanning-Application.pdf) ## Cost-Effective Tooling Solutions --- ## [Tool Breakage Detection](https://www.caroneng.com/result/tmac-cuts-tooling-costs-by-72-with-real-time-tool-breakage-detection) # Tool Breakage Detection \| TMAC Reduces Tooling Costs by 72% with Real-Time Monitoring | | | | --- | --- | | **Industry:** | Die Manufacturing | | **Machine:** | VMC | | **Material:** | Stainless Steel | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge This customer’s gun drilling process was very unstable and tool life was widely unpredictable. The customer was challenged with vertically drilling very tiny holes with microtools. Drills were breaking as often as every 3 to 15 holes. This excessive tool failure was caused by stray chips landing in the piloted holes. When the micro-drill followed to peck-drill the holes, it would often snap when it came into the piloted hole if chips were present. Breakage would go unnoticed until the operators made their rounds. Since the holes were piloted, they could not tell where the drilling stopped, and therefore, had to manually inspect thousands of pin-sized holes in the part to find the breakage location, extract the broken tool bit, and then restart the program from that point. ## Solution After implementing [TMAC](https://www.caroneng.com/products/tmac/), the customer has gained valuable insights into their cutting program, and the ability to pinpoint problem areas in the drilling to make the necessary adjustments to the program. TMAC monitors and displays real-time cutting and records all the data for analysis. TMAC has a built-in historical viewer that allows the user to interrogate the cuts on multiple levels to identify issues. Now, after optimizing the program with TMAC, they can drill several hundred holes before breaking a drill. The customer set an extreme limit with TMAC to interrupt the drilling if the drill encounters stray chips on the way into the piloted hole. TMAC stops and retracts the tool instantly when it encounters a chip, saving the tool from breaking. Then, using a touch probe, they check tool length and continue if the tool is good, or, error out, if not. This allows the tool to repeat this process until the chips are safely cleared without breaking the tool. To save downtime when tools do break, they set an undercut limit with TMAC to detect the broken tool location. If a tool breaks, it is identified on the subsequent hole with an undercut alarm (no contact with material), and the machine is stopped instantly. Utilizing the CNC position data provided by TMAC, (isolating the exact XYZ location of the CNC at any point in the monitored cut), they can precisely locate the hole where the tool broke for immediate extraction. ### Results - Reduced tooling budget allocation over 3 years by 72% - ROI for multiple machines equipped with [TMAC](https://www.caroneng.com/products/tmac/) was less than 6 months - Customer is getting the maximum life out of each drill - Downtime significantly reduced [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/9636-TMAC-Cuts-Tooling-Costs-by-72-with-Real-Time-Tool-Breakage-Detection.pdf) ## Accuracy with DTect-IT --- ## [DTect-IT Maintains Part Accuracy with Very Tight Tolerances](https://www.caroneng.com/result/dtect-it-maintains-part-accuracy-with-very-tight-tolerances) # DTect-IT Maintains Part Accuracy with Very Tight Tolerances | | | | --- | --- | | **Industry:** | Medical | | **Machine:** | Small VMC | | **Tooling:** | Standard | [![](https://www.caroneng.com/wp-content/uploads/DTect-IT-Logo-768x192.png)](https://www.caroneng.com/products/dtect-it/) ## Challenge The customer was robot loading long cylindrical parts into a rotary table collet on a vertical mill. They had a very tight tolerance to hold, so the position of the part in the collet was critical. The robot was not able to hold the position close enough (+/- 0.0003” tolerance) so they were looking for a way to measure the part after it was clamped in the collet. The cycle time was very short, so probing was ruled out. They had the idea of using a Keyence Digital Contact Sensor to measure the deviation from nominal and adjust the cutting program. ## Solution Caron Engineering’s sensor and software monitoring suite (DTect-IT) has an analog sensor option to easily connect and monitor any sensor with a 4-20ma signal, and up to four sensors can connect to a single analog module. The customer implemented [DTect-IT](https://www.caroneng.com/products/dtect-it/) to read the analog output of the Keyence Digital Contact Sensor mounted in the machine. With the analog module, the 4-20ma signal from the sensor can be converted to distance in inches or millimeters. Using the displacement unit conversion, this scale can be displayed on the DTect-IT analysis screen. DTect-IT can communicate to multiple CNC controls simultaneously, and separate analyses can be created for each CNC. A single DTect-IT with one analog module can communicate with up to four machines. This allowed the customer to set up a limit analysis with DTect-IT for each sensor to identify parameters for deviation and communicate the results to the respective CNC control. This deviation is used to adjust the program position. If deviation limits are exceeded or not reached, DTect-IT will automatically set an alarm in a variable in the machine to signify the alarm condition. This required no operator intervention after setup. **The program flow is as follows:** 1.) The robot loads a new part in the collet of the rotary table 2.) The machine program confirms load complete and closes the collet 3.) The machine sets variable to start DTect-IT analysis 4.) DTect-IT updates a variable with the current part displacement 5.) The program is adjusted by the value in the variable 6.) [DTect-IT](https://www.caroneng.com/products/dtect-it/) analysis is stopped 7.) Part is machined ### Results - Improved part quality and consistency - The overall part accuracy is within the 0.0003” tolerance - No additional cycle time was added using this in-process measuring DTect-IT monitoring the displacement of the Keyence Digital Contact Sensor [More About Product](https://www.caroneng.com/products/dtect-it/) [See More Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [Download](https://www.caroneng.com/wp-content/uploads/9209-DTect-IT-Maintains-Part-Accuracy-with-Tight-Tolerances.pdf) ## Error-Free CNC Tool Loading --- ## [ToolConnect Simplifies CNC Tool Loading and Reduces Errors](https://www.caroneng.com/result/toolconnect-eliminates-errors-loading-cnc-tools) # ToolConnect Simplifies CNC Tool Loading and Reduces Errors | | | | --- | --- | | **Industry:** | Automotive | | **Machine:** | VMC | [![](https://www.caroneng.com/wp-content/uploads/Tool-Connect-Color-match-768x238.png)](https://www.caroneng.com/products/toolconnect/) ## Challenge This customer has 6 identical vertical machining centers running the same part, so each machine has identical tooling. The biggest issue was operators moving tools from one machine to another (all machines are identical & making identical parts). When the operators noticed a tool had worn from one machine, they would just pull an identical tool from another machine, since the tool carousel is openly accessible. So, there was no accountability of the tools. In addition, the operators would not always take the time to get the tool information (geometry/wear/life) from the previous machine to the new machine which induces error into the process. In the rare cases when they did take the time to get the tool information, it caused downtime and was subject to fatfinger errors. ## Solution By implementing Caron Engineering’s [ToolConnect](https://www.caroneng.com/products/toolconnect/) RFID system, it is now impossible to cut if the wrong tool is in the machine without updating the necessary tool parameters, since the information travels with the tool. The ToolConnect system uses embedded RFID tags inside the tool holders. Each tag is written at the presetter and contains all the data for the specific tool, including geometry, wear, and tool life information. There is a file in ToolConnect that defines acceptable tolerances for each tool. ToolConnect will recognize if the wrong tool is in position and will not allow the process to continue. For this unique ToolConnect system, all of the transactions occur while the tool is in the spindle. Tools are read/written per the below (system overview) specifications after insertion and prior to removal from the spindle. The tool is measured by a laser in the machine, and tool offsets are updated directly to the wear table in the CNC. [ToolConnect](https://www.caroneng.com/products/toolconnect/) reads the wear table and updates the tag the next time the tool is in spindle position. The entire process is automated. If tools are used across multiple machines, the required tool data is transferred with the tool. No operator data entry is required. ##### System Overview – Specifications 1) Tool pot value on tag is compared to tool pot in which tool resides. If not corresponding, then an alarm is generated. 2) If tool pot values coincide then the tool geometry data on the tag is written into the CNC tool geometry table and the CNC wear table is set to 0. 3) The used tool life will be set to 0. 4) The tool status bit is set to used. 5) The machine ID will be programmed onto the tag. Tool READ/WRITE Description: Tool status bit = USED 1) Prior to removing the tool from the spindle, the values in the CNC wear tables will be written to the tag. 2) The used tool value in the CNC will be written to the tag. **Tool READ/WRITE Description: Machine ID mismatch** 1) Tool pot value on tag is compared to tool pot in which tool resides. If not coinciding, then an alarm is generated. 2) If the machine ID on the tag does not match the machine ID in ToolConnect, then the Machine ID set in ToolConnect is programmed on the tag. 3) The tool geometry and wear values from the tag will be written to the CNC offset table. 4) The full and used life values on the tag will be written to the tool life table in the CNC, provided that the assigned tool group. ### Results - Reduced setup time - Eliminated scrap and reworked parts due to incorrect tool data - Removed operator data entry errors and enabled proper tracking of each tool - Eliminated machine crashes due to wrong tool loaded [More About Product](https://www.caroneng.com/products/toolconnect/) [See More Results](https://www.caroneng.com/results/?_sft_product=toolconnect) [Download](https://www.caroneng.com/wp-content/uploads/9153-ToolConnect-Reduces-Setup-Time-and-Error-Proofs-the-Process-of-Loading-CNC-Tools.pdf) ## CNC Productivity Enhancement --- ## [Tool Monitoring Increases Productivity with 24/7 Lights-Out Machining](https://www.caroneng.com/result/tool-monitoring-enhances-lights-out-cnc-productivity) # Tool Monitoring Increases Productivity with 24/7 Lights-Out Machining | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | Multiple Machining Centers | | **Material:** | Titanium | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge An aerospace manufacturing company specializing in 4 & 5 axis machining was being ultra conservative with speeds and feeds, programming for the worst material condition to avoid tool breakage. They were running parts approximately 12-18 hours per day, and always attended by a machine operator. ## Solution The customer installed the [TMAC (Tool Monitoring Adaptive Control) System](https://www.caroneng.com/products/tmac/) on five (5) Okuma machining centers. TMAC has enabled them to get real data off the machines to show the programmers how the machines are reacting to their part programs. They have realized some very serious gains by implementing TMAC. To start, TMAC detects worn tooling during operation. Using the adaptive control feature, TMAC automatically slows the feed rate down during rough operations to keep the tool from breaking as it begins to deteriorate, allowing them to cut more parts per tool. These parts also contain a lot of air cutting. The TMAC adaptive control feature automatically increases the feed rate in these areas to reduce cycle time. They no longer need to be ultra conservative with their speeds and feeds, knowing TMAC will make the necessary adjustments for them. TMAC has also given them the confidence to run their machines overnight and during weekends, at times when there are no operators present. They can load up their pallet system and tool carousels and then walk away for the weekend. If TMAC detects a tool is worn, it will automatically call a redundant tool if it’s available in the carousel. The TMAC interrupt program will shuttle out pallets if there is an alarm, to automatically move to the next workpiece, eliminating machine downtime. They return to the shop on Monday and everything has already been cut, or the machine has stopped if TMAC has detected issues or exhausted its tooling or pallet supply. With [TMAC](https://www.caroneng.com/products/tmac/), their machines run 24/7. They are running the proper feed rates which has reduced cycle time by 15% – 26%. Their productivity has significantly increased through unattended operation and proper tool life management. And, with the real-time data, they can analyze their cutting and optimize their part programs. ### Results - Reduced cycle time up to 26% - Increased productivity with 24/7 lights-out machining - Optimized cutting programs - Maximized tool life with proper insights and management into their cutting operations [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/6666-Tool-Monitoring-Increases-Productivity-with-24-7-Lights-Out-Machining.pdf) ## Tool Wear Compensation --- ## [Automated Offset Adjustments Contribute to Unmanned Operations](https://www.caroneng.com/result/automated-tool-wear-compensation-software-contributes-to-unmanned-operations) # Automated Offset Adjustments Contribute to Unmanned Operations | | | | --- | --- | | **Industry:** | Contract Manufacturing Aerospace | | **Machine:** | Swiss Lathe | | **Material:** | Aluminum | [![](https://www.caroneng.com/wp-content/uploads/AutoComp-Color-Match-768x154.png)](https://www.caroneng.com/products/autocomp/) ## Challenge The customer was bidding an aerospace contract and needed to automate a lathe for a production part with extremely tight tolerances. In order to win the manufacturing contract, they knew they would require unmanned operations. Due to the tight tolerances, every part needed to be measured in the process. ## Solution The customer installed Caron Engineering’s [automated tool wear compensation software, AutoComp](https://www.caroneng.com/products/autocomp/). AutoComp automatically reads the measurement file from their electronic gauging device to determine if and how much compensation is required. Then, AutoComp directly compensates the CNC control, without any manual data entry or operator intervention. With AutoComp, the process is controlled automatically, without the extra labor of a machine operator having to manually adjust the tool offsets. AutoComp prevents the offsets from being adjusted incorrectly, to accurately maintain even the tightest tolerances. The implementation of [AutoComp](https://www.caroneng.com/products/autocomp/) assisted with this customer winning the aerospace contract. ### Results - Eliminated human error associated with manual offset adjustment and calculation - Maintained part accuracy with very tight tolerances The AutoComp run time display shows the measurement data for each dimension. Green indicates the part is good, yellow indicates compensation is required, and red indicates the part is out of tolerance. [More About Product](https://www.caroneng.com/products/autocomp/) [See More Results](https://www.caroneng.com/results/?_sft_product=autocomp) [Download](https://www.caroneng.com/wp-content/uploads/5369-Automated-Tool-Wear-Compensation-Software-Contributes-to-Unmanned-Operations.pdf) ## Cost Savings for Automotive --- ## [TMAC Saves $300K per Month for this Automotive Customer Machining Camshafts](https://www.caroneng.com/result/tmac-saves-300k-per-month-for-this-automotive-customer-machining-camshafts) # TMAC Saves $300K per Month for this Automotive Customer Machining Camshafts | | | | --- | --- | | **Industry:** | Automotive | | **Machine:** | Lathe | | **Material:** | Steel | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge A customer manufacturing camshafts for the automotive industry needed a solution for a very costly problem. Operators were loading tools incorrectly and failing to replace broken tools. Consequently, a necessary oil drain hole was not getting machined through the camshaft, leading to engine failures. Due to the repeated failure, this company was mandated to have all camshafts inspected by a 3rd party. This was costing them an additional $300,000 per month. ## Solution The customer implemented Caron Engineering’s TMAC system. TMAC is an [advanced tool monitoring system](https://www.caroneng.com/products/tmac/) that first learns the optimum power for each tool in cut and then compares it to user-defined parameters (limits) to monitor the cutting tools in real-time. By setting an undercut limit with TMAC, they were able to detect if the hole was actually being machined. The undercut limit is used to detect if not enough power is achieved based on the learned cutting data. In this case, not enough power indicated that the hole was not machined completely, and an alarm would alert the operator. In addition, a TMAC extreme alarm was set to alert the operator if a tool was broken. TMAC was able to safeguard the process to eliminate the operator error associated with tool loading and broken tools. By increasing process confidence, [TMAC](https://www.caroneng.com/products/tmac/) removed the need for the additional 3rd party inspection, resulting in substantial monthly cost savings. ### Results - Reduced costs by $300K/monthly by eliminating 3rd party inspection services - Eliminated operator errors to increase process confidence TMAC monitoring shows the undercut limit satisfied indicating the hole was drilled successfully [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/3674-TMAC-Saves-300K-for-this-Automative-Customer-Machining-Camshafts.pdf) ## TMAC Crash Prevention --- ## [TMAC Prevents a Costly Crash by Stopping this Extreme Condition in its Tracks](https://www.caroneng.com/result/tmac-prevents-a-costly-crash-by-stopping-this-extreme-condition-in-its-tracks) # TMAC Prevents a Costly Crash by Stopping this Extreme Condition in its Tracks | | | | --- | --- | | **Industry:** | Oil and Gas | | **Material:** | VMC | | **Tooling:** | CAT50 Tooling with Shell Mill | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge Unbeknownst to the customer, a robot loaded a part incorrectly into the work-holding. ## Solution This customer avoided a devastating crash since the machine was equipped with Caron Engineering’s [TMAC (Tool Monitoring Adaptive Control) System](https://www.caroneng.com/products/tmac/) monitoring the real-time power load on the tool. TMAC immediately registered the power spike as the power load deviated from the norm, triggering an extreme alarm. With TMAC’s direct interface to the CNC control, TMAC instantly stopped the machine before the next insert even came in contact with the material. Without any human intervention, Caron Engineering’s TMAC system shut the spindle off in time to save all the inserts and prevent the customer from destroying the work-holding. [TMAC](https://www.caroneng.com/products/tmac/) helped this customer avoid a costly crash by stopping this extreme condition in its tracks! ### Results - Allowed unattended operation - Protected the machine and workholding - Provided a fail safe for robot/automation errors TMAC stopped the machine before the next insert came in contact with the material. [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/7166-TMAC-Prevents-a-Costly-Crash-by-Stopping-this-Extreme-Condition-in-its-Tracks.pdf) ## Tool Wear Monitoring --- ## [Real Time Tool Monitoring Eliminates Downtime and Cuts Tooling Cost by 50%](https://www.caroneng.com/result/real-time-tool-wear-monitoring-eliminates-downtime-and-cuts-tooling-costs-by-50) # Real Time Tool Monitoring Eliminates Downtime and Cuts Tooling Cost by 50% | | | | --- | --- | | **Industry:** | Firearms Manufacturing | | **Machine:** | Horizontal Lathe | | **Material:** | Hardened 4140 Steel | | **Tooling:** | 1/2" 5 Flute End Mill | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge This customer, machining high-volume firearm safety levers, was experiencing costly collet replacement and downtime due to operators running tools to their breaking point. They were making decisions based on tool life guestimates and time in cut. ## Solution The customer implemented Caron Engineering’s [adaptive tool monitoring system, TMAC](https://www.caroneng.com/products/tmac/). TMAC calculates the power consumed over the duration of the cut to calculate tool wear. As tools wear, TMAC is calculating this in real-time, and the measured wear is easily viewed by the shading of the monitored cut. If a tool reaches the wear percentage (limit), TMAC finishes the cut and expires the tool. If a tool breaks, [TMAC](https://www.caroneng.com/products/tmac/) stops the machine and retracts the tooling before damage can occur. By assessing tool wear prior to a tool breaking, this customer has dialed in their wear limit parameters so well that the tool is safely pushed to a point of real tool wear without going over the edge and breaking. This allows the customer to get the maximum life out of the tool. They have the work wear limit set at 95% to retire the tool. Beyond that, the likelihood of breaking is extremely high. ### Results - 50% reduction in tooling costs - Eliminated damage and downtime from tool breakage TMAC Data Viewer – cuts are overlaid to show the new tool in cut requiring less cutting power (gray line) compared to the (yellow shaded) worn tool previously expired by TMAC [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/10165-Real-Time-Tool-Wear-Monitoring-Eliminates-Downtime-and-Cuts-Tooling-Costs-by-50-2.pdf) ## Tool Wear Monitoring --- ## [DTect-IT Monitors Tool Wear and Breakage of a 2.7mm Drill and 3.05mm Reamer](https://www.caroneng.com/result/dtect-it-monitors-tool-wear-and-breakage-of-a-2-7mm-drill-and-3-05mm-reamer) # DTect-IT Monitors Tool Wear and Breakage of a 2.7mm Drill and 3.05mm Reamer | | | | --- | --- | | **Industry:** | Automotive | | **Machine:** | Mill-Turn | | **Material:** | Cast Aluminum | | **Tooling:** | 2.7mm Drill, 3.05mm Reamer | [![](https://www.caroneng.com/wp-content/uploads/DTect-IT-Logo-768x192.png)](https://www.caroneng.com/products/dtect-it/) ## Challenge This automotive manufacturer was using a competitor’s product to try and monitor a very small drill and reamer cutting cast aluminum. They noticed the monitoring system was slowing the process and adding several seconds to the cycle time for every part. ## Solution The customer needed a better solution, so they implemented Caron Engineering’s versatile [sensor analysis system](https://www.caroneng.com/products/dtect-it/), DTect-IT. Using DTect-IT the customer is now successfully monitoring breakage and wear on the drill and reamer that create this hole (pictured right). For this application, DTect-IT uses a high precision power sensor to measure the cutting loads of the 2.7mm drill and 3.05mm precision reamer, (with the reamer enlarging the hole by .08mm). [DTect-IT](https://www.caroneng.com/products/dtect-it/) is efficiently identifying broken, missing, and worn tools with no negative impact on the part cycle time. ### Results - Successfully detecting broken, missing, and worn micro-tools - No additional cycle time was added using real-time monitoring [More About Product](https://www.caroneng.com/products/dtect-it/) [See More Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [Download](https://www.caroneng.com/wp-content/uploads/9111-DTect-IT-Monitors-Tool-Wear-and-Breakage-of-a-2.7mm-Drill-and-3.05mm-Reamer.pdf) ## Inspection Improves Productivity --- ## [In-Process Inspection Plays a Key Roll in Productivity Increases for this Customer](https://www.caroneng.com/result/in-process-inspection-plays-a-key-roll-in-productivity-increases-for-this-customer) # In-Process Inspection Plays a Key Roll in Productivity Increases for this Customer | | | | --- | --- | | **Industry:** | Contract Manufacturing | | **Machine:** | Swiss Lathe | | **Material:** | Aluminum | [![](https://www.caroneng.com/wp-content/uploads/AutoComp-Color-Match-768x154.png)](https://www.caroneng.com/products/autocomp/) ## Challenge The customer wanted a fully automated work cell, with a goal of increasing productivity by 50%. ## Solution The company implemented multiple systems to increase productivity by 200%. One of these systems being Caron Engineering’s AutoComp software. “The automated cell uses in-process inspection, which saves the company both time and labor costs. The robot performs a thorough inspection process for quality control purposes, taking the last part to be placed in a tray through an ultrasonic wash station, then to a CMM for inner-diameter measurement and a laser-profile inspection machine for outer-diameter measurement. The data is processed by [Caron Engineering’s AutoComp Software](https://www.caroneng.com/products/autocomp/) and fed back to the producing machine to enable tool-wear compensation that maintains part accuracy. Software-driven inspection data for automatic tool offsets eliminates human error, thus improving product quality and reducing scrap.” ### Results - Increased productivity by 200% using automation technology including Caron Engineering’s [AutoComp Software](https://www.caroneng.com/products/autocomp/) The AutoComp display shows the measurement data for each dimension and tool life. [More About Product](https://www.caroneng.com/products/autocomp/) [See More Results](https://www.caroneng.com/results/?_sft_product=autocomp) [Download](https://www.caroneng.com/wp-content/uploads/4899-In-Process-Inspection-Plays-a-Key-Roll-in-Productivity-Increases-for-this-Customer.pdf) ## Machining Efficiency Improvement --- ## [Aluminum Hydraulic Manifold Machined 24% Faster Using TMAC Optimization](https://www.caroneng.com/result/tmac-reduces-cycle-time-by-24-machining-an-aluminum-hydraulic-manifold) # Aluminum Hydraulic Manifold Machined 24% Faster Using TMAC Optimization | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | 4 Axis HMC | | **Material:** | Aluminum | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge ## Solution The customer implemented Caron Engineering’s [TMAC (Tool Monitoring Adaptive Control) System](https://www.caroneng.com/products/tmac/), hoping to achieve 10% cycle time savings. TMAC has an adaptive control feature that automatically regulates the machine tool feed rate as the tool is cutting through the material. It optimizes cutting by learning the optimum power for each tool and then automatically adapts the feed rate in real-time through variations in material, tooling, and depth of cut. TMAC was able to reduce cycle time by ramping up the feed rate through air cutting and lighter cuts. The results with TMAC exceeded the customer’s expectations by reducing the cycle time to less than 13 hours, for an overall savings of 24%. By maintaining a constant tool load with [TMAC](https://www.caroneng.com/products/tmac/), the customer had the added benefit of extended tool life. ### Results - Reduced cycle time by 24% - Extended tool life by maintaining a constant cutting power [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/5947-Aluminum-Hydraulic-Manifold-Machined-24-Faster-Using-TMAC-Optimization.pdf) ## TMAC Tool Management --- ## [TMAC Prevents Tool Failure and Boosts Efficiency on High-Value $150K Part](https://www.caroneng.com/result/tmac-reduces-cycle-time-and-prevents-tool-breakage-on-a-150k-part) # TMAC Prevents Tool Failure and Boosts Efficiency on High-Value $150K Part | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | HMC | | **Material:** | 5834 Inconel (cast) | | **Tooling:** | 1/2" End Mill & Associated Drills | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge The customer is drilling 100 + holes in the flange on an engine case. The part program has to incorporate a tool check process to ensure the tool isn’t breaking, which is increasing the cycle time. The customer is also profiling and scalloping the flange on the engine case. Due to the varying cutting conditions, the feed rate must be set to accommodate the worst material condition, causing a lengthy cycle time of 25 hours. ## Solution Using Caron Engineering’s [TMAC (Tool Monitoring Adaptive Control) System](https://www.caroneng.com/products/tmac/), the CNC program no longer requires the tool check process because TMAC monitors the tools in real-time during cutting, and alarms the machine when a drill gets dull. This eliminates the need for manual tool checks and they can confidently run the process without the concern of scrapping a $150K part. To help with the lengthy cycle time they implemented the adaptive control option with TMAC. This feature automatically adjusts the feed rate in real-time to speed up through air cutting and lighter cuts, and slow down through heavier cuts and as tools get dull. With adaptive control, the scallop milling cycle time has been reduced by 60%. In addition, the customer is also able to determine which of their vendors regrinds their tools better. [TMAC](https://www.caroneng.com/products/tmac/) displays the actual power the tool is generating allowing them to choose the ### Results - Reduced cycle time by 60% - Eliminated the need for manual tool checks - Provided insights into the tool quality for vendor selection [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/5834-TMAC-Prevents-Tool-Failure-and-Boosts-Efficiency-on-High-Value-150K-Part.pdf) ## CNC Data Entry Solution --- ## [ToolConnect Prevents CNC Data Entry Errors and Downtime](https://www.caroneng.com/result/toolconnect-eliminates-costly-downtime-due-to-human-data-entry-errors) # ToolConnect Prevents CNC Data Entry Errors and Downtime | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | 5 Axis Machining Center | [![](https://www.caroneng.com/wp-content/uploads/Tool-Connect-Color-match-768x238.png)](https://www.caroneng.com/products/toolconnect/) ## Challenge A customer in the aerospace industry experienced numerous machine crashes due to machine operators accidentally entering a wear offset in place of a geometry offset. A machine would typically be out of commission for two weeks for repairs, resulting in over $100K in lost production time alone; not including repair costs. ## Solution The customer needed a solution to eliminate these costly operator data-entry errors. The customer implemented Caron Engineering’s [ToolConnect](https://www.caroneng.com/products/toolconnect/), a RFID tool identification system. ToolConnect works in combination with a tool presetter to automatically transfer tool presetter data to (and from) the CNC control. The tool presetter measures the tool and writes all the tool data to the RFID tag which is embedded in the tool holder. ToolConnect reads the RFID tag at the machine read-station, displays all tool information on the HMI, and guides the user through the customer-defined tool load process. The operators no longer manually enter the tool data, it happens automatically. ToolConnect reads and updates all geometry and wear offsets to the control. As an added failsafe, if an operator tries to load an incorrect tool, or a tool in the wrong pot, ToolConnect will alert the operator. In addition to eliminating excessive costly downtime due to human errors, the customer has also noticed the added benefit of part cycle time savings. They were using in-machine tool setting to measure the tools, which was utilizing valuable spindle time. By employing ToolConnect and a tool presetter, the parts are continuously being cut while the tools are being measured simultaneously offline. They have instantly saved almost 60 seconds per tool (28 tools) by eliminating the initial in-machine tool measurement and manual data entry. In-machine laser tool setting is still used to adjust for tool size after cutting. The benefits and immediate ROI with [ToolConnect](https://www.caroneng.com/products/toolconnect/) surpassed the customer’s expectations, and they have since placed an order to outfit 33 of their machine tools with ToolConnect. ### Results - Instant ROI with [ToolConnect](https://www.caroneng.com/products/toolconnect/) - Eliminated machine crashes from tool data-entry errors - Saved 60 seconds per tool (setup) with off-line measurement - Followed up with a 33 unit ToolConnect order [More About Product](https://www.caroneng.com/products/toolconnect/) [See More Results](https://www.caroneng.com/results/?_sft_product=toolconnect) [Download](https://www.caroneng.com/wp-content/uploads/7620-ToolConnect-Prevents-CNC-Data-Entry-Errors-and-Downtime.pdf) ## Vibration Monitoring Solutions --- ## [Spindle Vibration Monitoring Reduces Scrap from Bar Stock Defects](https://www.caroneng.com/result/spindle-vibration-monitoring-reduces-scrap-from-bar-stock-defects) # Spindle Vibration Monitoring Reduces Scrap from Bar Stock Defects | | | | --- | --- | | **Industry:** | Production Machining | | **Machine:** | Swiss-Style Lathe | | **Material:** | Brass | [![](https://www.caroneng.com/wp-content/uploads/DTect-IT-Logo-768x192.png)](https://www.caroneng.com/products/dtect-it/) ## Challenge A customer has a Swiss-style lathe, running unattended, with an auto-fed bar feeder delivering 12-foot bar stock to the machine. This customer was scrapping a significant amount of parts due to irregularities in the bar causing dimensional and finish errors. ## Solution The customer implemented Caron Engineering’s Spindle Vibration Monitoring by mounting a [DTect-IT](https://www.caroneng.com/products/dtect-it/) vibration sensor to the barfeeder and connected it to the Fanuc control to monitor certain characteristics of the lathe program. The customer set the vibration thresholds and then programmed an acceptable RPM range for compensation. During machining, DTect-IT monitored the vibration levels on the barfeeder. If vibration was within the acceptable limits, nothing was changed. If vibration levels exceeded the userdefined limits, DTect-IT alerted the CNC control to reduce the spindle RPM within the acceptable range to compensate for the excessive vibration. DTect-IT then informed the CNC control when the vibration levels were (1) acceptable or (2) generated an alarm to stop the machine if the RPM had to be reduced beyond the lowest threshold to make good parts. Using DTect-IT, the customer has eliminated scrap parts due to irregularities in the bar stock. Excessive bar feeder vibration also has a negative impact on bearing life. With [DTect-IT](https://www.caroneng.com/products/dtect-it/) monitoring the vibration, they have realized the additional benefit of increased spindle bearing life. ### Results - Eliminated scrap due to imperfections in material bar stock - Improved spindle life by regulating vibration levels [More About Product](https://www.caroneng.com/products/dtect-it/) [See More Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [Download](https://www.caroneng.com/wp-content/uploads/7022-Spindle-Vibration-Monitoring-Reduces-Scrap-from-Bar-Stock-Defects.pdf) ## Runout Detection Case Study --- ## [Machining Runout Detection Eliminates Scrap Caused by Chip Interference](https://www.caroneng.com/result/machine-runout-detection-case-study) # Machining Runout Detection Eliminates Scrap Caused by Chip Interference | | | | --- | --- | | **Industry:** | Automotive | | **Machine:** | HMC | | **Material:** | Cast Aluminum | | **Tooling:** | 8.6mm Drill | [![](https://www.caroneng.com/wp-content/uploads/DTect-IT-Logo-768x192.png)](https://www.caroneng.com/products/dtect-it/) ## Challenge This customer was repeatedly machining out of tolerance holes in the engine head due to excessive runout of their tooling. The runout was the result of metal adhering to the taper of the tool holder during a tool change causing the tool to run out when contacting the material. This resulted in elongated and oversized bored holes on the engine head. The entire engine head had to be scrapped, which was extremely costly and unpredictable, often occurring multiple times per shift. ## Solution The customer implemented Caron Engineering’s DTect-IT with a vibration sensor to perform a frequency analysis of the rotating tool prior to cutting. The frequency at which the analysis is carried out is based on the RPM of the tool. First, DTect-IT learns the normal magnitude of the tool when properly loaded. When a chip significant enough to create the runout penetrates the tool clamping area there is a resultant increase in the (vibration) signal amplitude measured with DTect-IT, which will generate an alarm. The part program checks for the DTect-IT alarm and stops the process before a bad part is produced. The program will then initiate a tool change in response to the DTect-IT alarm to remove and reinsert the tool, attempting to clear the chip from the tool. If this is successful, machining will proceed. If it is unsuccessful, DTect-IT will stop the process and signal the operator to intervene. ### Results - Eliminated scrap - Maximized machine uptime - Reduced inspection time (increased process confidence) [More About Product](https://www.caroneng.com/products/dtect-it/) [See More Results](https://www.caroneng.com/results/?_sft_product=dtect-it) [Download](https://www.caroneng.com/wp-content/uploads/9618-Tool-Health-Check-Application-Eliminates-Scrap-from-Runout-Caused-by-Chip-Interference.pdf) ## Grinding Efficiency Solutions --- ## [TMAC Optimizes Grinding Efficiency and Prevents Costly Spindle Failure in Aerospace Manufacturing](https://www.caroneng.com/result/tmac-optimizes-grinding-efficiency-and-prevents-costly-spindle-failure-in-aerospace-manufacturing-2) # TMAC Optimizes Grinding Efficiency and Prevents Costly Spindle Failure in Aerospace Manufacturing | | | | --- | --- | | **Industry:** | Aerospace | | **Machine:** | Grinding Machine | | **Tooling:** | Standard | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge A manufacturer of aircraft engine components was machining precision parts on a Mägerle MFP 30 grinding machine, where process consistency and uptime are critical. The operation relied on a canned dressing cycle to maintain grinding wheel condition—a fixed routine that did not account for real-time cutting conditions. While effective for quality, this approach added unnecessary cycle time and limited process efficiency. The customer initially deployed TMAC(Tool Monitoring Adaptive Control) to gain deeper insight into the grinding process and identify opportunities to reduce cycle time without compromising part quality. Dressing is essential in grinding to restore wheel sharpness and ensure dimensional consistency, but the existing canned cycle operated independently of actual tool condition—resulting in excess dressing and lost productivity. ## Solution Using TMAC’s real-time process monitoring, the customer transitioned from time-based, canned dressing to trigger-based dressing. Instead of dressing on a fixed schedule, TMAC now initiates dressing only when monitored process signals deviate from established limits. This shift delivered immediate benefits: - Reduced unnecessary dressing cycles - Shorter overall cycle times - Improved grinding efficiency while maintaining strict quality standards #### An Unexpected Save While monitoring the grinding process, TMAC—using integrated vibration sensor analysis—detected an abnormal spindle condition on the dressing wheel. TMAC issued an alert indicating a developing anomaly. Operators paused production to investigate and confirmed that the spindle was nearing failure. By acting early, the customer was able to retire the spindle proactively rather than experiencing an in-process failure. This avoided a full spindle rebuild, prevented collateral machine damage, and significantly reduced downtime compared to a catastrophic failure scenario. #### The Results - Cycle time reduced through adaptive, trigger-based dressing - Early detection of spindle degradation - Avoided catastrophic spindle failure and extended downtime - Lower maintenance and repair costs - Increased confidence in process and machine health monitoring #### The Impact Following this experience, the customer has continued to trust TMAC’s guidance and has expanded its use across additional machines. TMAC’s spindle bearing health monitoring is now active throughout more of their grinding operations, providing early warnings, protecting critical assets, and supporting long-term reliability. TMAC has become a trusted tool not only for process optimization, but also for predictive machine protection—delivering measurable time savings, cost avoidance, and peace of mind in a high-precision aerospace environment. ### Results - Reduced cycle time with adaptive, trigger-based dressing - Prevented spindle failure and downtime through early detection - Lowered maintenance costs with improved machine health confidence Spindle Bearing Health is monitored with custom sensors and analyzed and visualized on TMAC interface as shown. [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/12121_TMAC-Optimizes-Grinding-Efficient_Manufacturing-1-1.pdf) ## MiConnect Automation Solution --- ## [MiConnect Technology Powers Automation for this Medical Device Manufacturer](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device) # MiConnect Technology Powers Automation for this Medical Device Manufacturer | | | | --- | --- | | **Industry:** | Medical | | **Machine:** | Mill-Turns and Turning Centers | [![](https://www.caroneng.com/wp-content/uploads/MiConnect-1-768x141.png)](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/) ## Challenge A prominent medical device manufacturer faced a complex challenge while developing a new manufacturing cell for its production line. Tasked with creating an efficient, fully automated environment, the company’s goals required connecting multiple machines and subsystems, ensuring real-time data flow, and synchronizing information across various CNC controls and supervisory systems. The manufacturing cell included two mill-turn machines, one turning center, two coordinate measuring machines (CMMs), and a dual gantry robot system. Achieving true lights-out manufacturing required advanced communication between these devices and the company’s Manufacturing Execution System (MES). ## Solution To meet these requirements, the customer selected Caron Engineering’s [MiConnect Technology](https://www.caroneng.com/miconnect-technology/) as the core cell controller. MiConnect is a versatile and intuitive application builder for manufacturing, and an ideal solution for this complex integration. To start, the customer mapped out a flow chart of the devices and data stream, and leveraging MiConnect with its inventory of pre-built device drivers and flowchart-based design interface, Caron Engineering created a customized application to fit their specific requirements.MiConnect provided a centralized platform to manage data flow, synchronize communication between all manufacturing devices, and seamlessly integrate with MES and ERP systems. One of the standout features of this implementation was the ability to queue and manage jobs directly from the MES. Operators could input job orders into the MES, which MiConnect translated to the Robot PLC, directing the cell to produce specific parts in precise quantities. The MiConnect interface also allowed operators to reorder job queues in real-time, enabling flexibility in production prioritization. A custom dashboard displayed real-time job progress, including completed jobs, enhancing visibility and efficiency. This automation eliminated manual paperwork and intervention, allowing the cell to start and run unattended as new jobs were continuously queued. MiConnect’s integration for advanced maintenance monitoring was another key component. By interfacing with the MES, the system checked and enforced preventive maintenance (PM) schedules for all cell components, including CNC machines, CMMs, and robots. If a device required maintenance, MiConnect locked out that portion of the cell while allowing other areas to continue running, ensuring maximum uptime and efficiency. Additionally, automatic chuck changes were introduced—something never before done in the U.S. This process, primarily facilitated by MiConnect, ensured the correct hardware was in place before initiating a job, reducing errors and optimizing machine utilization. The MiConnect solution delivers both the simplicity required for basic processes and the sophistication needed for comprehensive control and communication between CNCs, measurement devices, and robotics, enabling seamless lights-out manufacturing. MiConnect ensures that each manufacturing operation is executed correctly before advancing to the next step. With customized user screens, customers can display all critical process information directly on the HMI, streamlining operations and enhancing efficiency. MiConnect provides a unified platform that supports multiple communication protocols enabling rapid customization without coding. The flexibility of the software allows for on-the-fly changes, which is essential when integrating high-level, complex automation systems. Additionally, MiConnect standardizes communication to a single Ethernet connection for all devices, reducing network complexity. Unlike traditional SCADA or machine-level software solutions, MiConnect functions as a mid-tier solution, bridging low-level automation protocols (FOCAS, MODBUS TCP, REST) with high-level MES/job modeling. This versatility makes it a cost-effective alternative to custom integrations, significantly reducing both development time and ongoing maintenance complexity. #### **RFID Tool Management and Automated Tool Wear Compensation** The setup also called for advanced automated tool management and real-time compensation solutions, which Caron Engineering’s technology portfolio provided. Using [ToolConnect](https://www.caroneng.com/products/toolconnect/), Caron Engineering’s RFID-based tool data management system, the company automated tool loading and tracking, improving both accuracy and efficiency. #### **The Results** - **Faster Implementation:** Caron Engineering provided a tested MES integration model within days—a process that traditionally takes weeks. - **Dynamic Adjustments:** MiConnect allowed real-time process changes, essential for implementing new automation features like automatic chuck changes. - **Cost Savings:** Without MiConnect, the manufacturer would have needed multiple custom software solutions, significantly increasing costs and requiring extensive development time. - **Simplified Network:** MiConnect consolidated communication to simple Ethernet connections, reducing network complexity and integration challenges. - **Lights-Out Manufacturing**: The automation integration of the all the systems with MiConnect allowed the cell to run continuously, and completely unattended. This customer success with MiConnect not only optimized this manufacturing cell but set a new automation standard across its global operations. With the ability to scale and adapt to evolving production needs, MiConnect continues to drive efficiency, flexibility, and innovation in the company’s automated manufacturing strategy. ### Results - Allowed for continuous, unattended operations - Delivered MES integration in days, not weeks - Enabled real-time process changes - Reduced the cost of custom software development MiConnect provides comprehensive interconnectivity and control across all devices and systems in a manufacturing environment. [More About Product](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/) [See More Results](https://www.caroneng.com/result/miconnect-technology-powers-automation-for-medical-device/) [Download](https://www.caroneng.com/wp-content/uploads/10928_MiConnect-Cell-Controller-for-Automation_Medical-Manufacturing-2.pdf) ## Tool Monitoring System --- ## [Tool Monitoring Recovers Lights Out Operation for Brass Parts Manufacturer](https://www.caroneng.com/result/tool-monitoring-recovers-lights-out-operation) # Tool Monitoring Recovers Lights Out Operation for Brass Parts Manufacturer | | | | --- | --- | | **Industry:** | Contract Manufacturing | | **Machine:** | Horizontal Turning Lathe | | **Material:** | Brass | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge The customer was operating a fully automated, lights-out machining cell using a CNC turning lathe to produce custom cast and machined brass parts. The part was machined with an aggressive cycle time of just 44 seconds per part, and machining ran unattended overnight to maximize production efficiency. However, one night, the robotic arm misaligned a part during loading, damaging the fixture. The error went undetected, and over 400 defective parts were machined before the team returned the next morning—resulting in substantial material waste, fixture replacement, and costly downtime. For a high-speed operation machining forged brass, even one night of unmonitored failure had major financial consequences. The one missing piece in their automated process was the ability to monitor and control the cutting process and automation in real time—ensuring errors like this could be caught and corrected before escalating. ## Solution To mitigate the risk of unmonitored errors in their automated cell, the customer purchased Caron Engineering’s [Tool Monitoring Adaptive Control (TMAC) system](https://www.caroneng.com/products/tmac/). This solution integrates power sensors to continuously monitor the spindle’s real-time cutting power, allowing it to learn the cutting process and precisely detect tool wear and breakage. TMAC learns the optimal power for each toolpath—establishing upper and lower power thresholds based on the learned optimum power for each tool and cutting section. If cutting power deviates from these limits, TMAC reacts instantly, stopping the machine within 5 milliseconds of an extreme alarm to prevent damage to the tool, part, and fixture. Based on learned limits, TMAC will register an alarm if _**any**_ condition deviates beyond the acceptable cutting parameters and stop the process. Now if the robot loads the part incorrectly, TMAC will stop the process before any damage can occur. This protection eliminates the risk of mass scrap and costly downtime, allowing the customer to confidently run 24/7 unattended production with consistent part quality and process control. In a fully automated, lights-out environment, TMAC plays a critical role beyond just protecting equipment. In addition to safeguarding the machine and monitoring tool wear and breakage in real time, TMAC ensures that all cutting conditions are properly met. Without TMAC, there is no system verifying that every feature is machined to specification—or stopping the process when they’re not. By actively monitoring each cut, TMAC guarantees part quality and process control—especially when no operator is present. **The Results** - **Eliminated Large-Scale Scrap:** Catches the first failure event to prevent hundreds of defective parts. - **Validated Cutting Conditions:** Ensures all machining operations stay within defined tolerances. - **Minimized Downtime:** Reacts in milliseconds to avoid extended fixture or spindle damage. - **Increased Automation Confidence:**Enables reliable, lights-out machining with built-in process oversight. ### Results - Prevented Costly Scrap - Safeguarded Critical Machining Processes - Minimized Unplanned Downtime - Enabled Reliable Unattended Operations [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/12445-Tool-Monitoring-Recovers-Lights-Out-Operation-for-Brass-Parts-Manufacturer-1.pdf) ## Predictive Quality Empowerment --- ## [TMAC AI Empowers Predictive Quality and Root-Cause Intelligence for Precision Manufacturing](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing) # TMAC AI Empowers Predictive Quality and Root-Cause Intelligence for Precision Manufacturing | | | | --- | --- | | **Industry:** | Precision Machining | | **Machine:** | Large Scale Horizontal Machining Centers | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge A leading manufacturer of complex precision components relies on Caron Engineering’s TMAC (Tool Monitoring Adaptive Control System) to oversee production across its high-volume, automated machining cells. These cells feature large horizontal machining centers equipped with robotic loading and advanced process monitoring—designed for maximum productivity and consistency. Despite these sophisticated systems, the manufacturer faced a persistent challenge: pinpointing where in the machining process quality issues originated. Problems that began early—often during roughing or semi-finishing—were sometimes not detected until final inspection, by which point valuable time, tooling, and material had already been lost. Machining variability made it difficult to determine whether deviations were caused by tool wear, insert condition, or material differences. While TMAC safeguarded and optimized the process in real time—monitoring all cutting parameters and capturing detailed data—engineers needed deeper visibility into that data to analyze trends, detect subtle variations, and isolate root causes across multiple operations and cells before quality was affected. They needed a tool that could: - Automatically flag suspect parts in real time - Link every monitored cut to a serialized part ID - Provide historical cutting signatures for traceability and quality verification - Reduce the time required to investigate and validate process anomalies ## Solution [TMAC ai](https://www.caroneng.com/tmac-ai/) ™, an advanced add-on to Caron Engineering’s TMAC system—developed with production-monitoring leader Datanomix—introduced a new level of predictive process control and manufacturing intelligence. The software automatically flags anomalies, builds historical process baselines, and gives engineers instant access to detailed data for every part, tool, and operation. Today, TMAC ai™ acts as the central hub for process health across multiple machining cells, visualizing data and trends to deliver unprecedented visibility—from roughing to finishing—on every component produced. ### **Turning Data into Process Intelligence** The Suspect Parts Review feature has become one of the manufacturer’s most valuable tools, fundamentally changing how engineers troubleshoot, analyze, and ensure part quality. ### **Building the Gold Standard** TMAC ai™ uses machine learning and real-time cutting data to establish a baseline of normal operation. By analyzing spindle power and other cutting parameters, it builds a “gold standard” process signature—the ideal cutting profile for a good part. From this, it defines a dynamic “blue band” of acceptable variation that automatically adapts to real cutting conditions. Any cycle that deviates beyond this range is flagged for review, allowing engineers to identify potential process issues before they affect downstream operations. ### **Fast Root-Cause Identification** Instead of manually searching through TMAC data across multiple machines, engineers are automatically alerted when anomalies occur and can quickly investigate using the Suspect Parts Dashboard. Parts are organized by machine and operation, enabling instant access to cutting analytics, historical comparisons, and detailed tool data. By comparing signatures, they can determine whether an anomaly resulted from a tool, material change, robot variation, or fixture shift—and take corrective action immediately. > **_“I used to spend hours—or even days—trying to find the root cause of a part defect. Now I can review multiple machines and get a full process and quality overview in about 30 minutes.”_** ### **Traceability and Targeted Containment** Every machined part is serialized and tracked in TMAC ai™, giving engineers complete visibility into its production history. They can confirm whether a part meets the gold standard or trace back to the exact tool and operation that produced it. When a suspect condition is detected, containment is precise—only the affected serial IDs are flagged for review while production continues uninterrupted. This targeted approach has reduced troubleshooting time from multiple shifts to just minutes, dramatically improving uptime and responsiveness. > **_“The value is the speed to go back in time and troubleshoot. What once took days now takes minutes.”_** ### **Process Evolution Through Insight** Engineers now use TMAC ai™ to correlate data patterns across operations, revealing how tool-wear settings, cutting conditions, and loading inconsistencies influence performance downstream. The system highlights recurring signatures that signal potential instability, helping the team make proactive adjustments. For example, TMAC ai™ revealed that mid-process tools were not being replaced at optimal intervals, placing excess load on finishing tools. By optimizing tool-wear limits for each stage, the team now achieves maximum tool life and balanced performance across the entire machining process. These insights have helped establish data-driven accountability and more robust processes—enabling proactive improvement before quality or productivity are affected. ### **Tool Life Visibility and Accountability** Tool life trending and analysis through TMAC ai™ have given the team a new level of control, insight, and cost savings. They Can: - Track tool wear in real time and see exactly when a tool begins to produce nonconforming parts. - Correlate tool wear with part quality and process stability. - Identify when performance begins to drift or when tool changes have been handled inconsistently. - Confidently extend tool life when data confirms cutting stability—reducing unnecessary changes and saving significantly on consumable costs. > _**“When I see a tool at 100% life consistently making good parts, I know I can safely push it further. The data takes the guesswork out—it’s proof.”**_ The result is lower tooling costs, greater process consistency, and smarter decision-making across the operation. ### **The Impact** By implementing TMAC ai™, the manufacturer achieved: - Troubleshooting time reduced from days to minutes - Accurate root-cause analysis through real-time signatures - Complete traceability and warranty confidence - Reduced tooling costs through data-driven optimization - Continuous process improvement across machining cells - Minimal downtime by isolating only affected parts > _**“We now have process control, we deliver quality parts, and we can prove it. TMAC ai™ gives us the data to back it up and supports our goal of being a trusted supplier of choice.”**_ ### **Conclusion** For this precision manufacturer, TMAC ai™ has elevated TMAC from a real-time monitoring system to a predictive intelligence platform that turns data into actionable insight. By combining TMAC’s robust adaptive control with AI-driven analytics, they’ve built a manufacturing environment defined by traceability, reliability, and proof of quality—empowering their team to deliver excellence with every part, every time. ### Results - Cut troubleshooting from days to minutes with rapid root cause isolation - Reduced downtime and tooling costs by isolating suspect parts and optimizing programs - Ensured full part traceability and warranty confidence across production [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/12781_TMAC-AI_Precision-Manufacturing-1-1.pdf) ## CNC Chip Prevention --- ## [From Notification to Protection: Automating Chip Overflow Prevention with MiConnect](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect) # From Notification to Protection: Automating Chip Overflow Prevention with MiConnect | | | | --- | --- | | **Industry:** | Contract Manufacturing | | **Machine:** | Chip Conveyor | | **Material:** | Hardened 4140 Steel | [![](https://www.caroneng.com/wp-content/uploads/MiConnect-1-768x141.png)](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/) ## Challenge A high-volume production shop was experiencing recurring issues with chip accumulation while machining 4140 steel in an unattended bar-fed application. The existing workflow relied on a technician noticing when the chip bin needed to be emptied and manually stopping production. In the fast pace of a busy shop floor, this was often missed. As a result: - Chip bins overflowed - Stringers and chips were reintroduced into the chip conveyor - The chip conveyor required multiple hours of repair - Significant downtime and lost production accumulated A routine maintenance task was consistently escalating into extended downtime and equipment risk. ## Solution The production shop implemented a solution built around **Caron Engineering’s MiConnect automation platform — a flexible low-code application builder that connects machines, devices, and control systems —** integrating it with their production monitoring system, OnTakt. The production monitoring system could receive a signal and generate a notification that the team needed to perform the preventive maintenance task, but it was unable to stop the process to ensure that the task was completed. Leaving the response timing dependent on personnel availability. **MiConnect transformed that signal into controlled action**. A laser sensor was integrated into the automation cell and aligned with the chip conveyor to detect when the chip bin reached a preset fill level. When that threshold is met: - The production monitoring system (OnTakt) flags the condition - MiConnect reads the state change in real time - MiConnect writes directly back to the control, signaling a stop - Production pauses until the bin is physically emptied With MiConnect integrated, the monitoring signal transitions from passive notification to controlled intervention. When the preset chip threshold is reached, MiConnect writes directly to the machine control to stop production, requiring the bin to be emptied before machining resumes. Instead of relying on someone to catch the issue in time, the system now enforces the correct process response. ## The Result What previously resulted in hours of downtime is now resolved in minutes. MiConnect continuously monitors the variable state from the OnTakt production monitoring system and executes a controlled stop when required. Once the bin is emptied, production resumes without incident. The outcome: - No chip overflow - No stringer-related damage - No extended chip conveyer repairs - No unexpected downtime The shop can now confidently run unattended overnight and through weekends, knowing that chip accumulation will not compromise the machine’s health or create extended downtime. Even more importantly, this solution established a repeatable automation framework that can be deployed across additional cells — turning a reactive process into a standardized safeguard. ### Results - Reduced downtime from multiple hours to minutes - Protected the chip conveyer and machine components - Enabled confident unattended production - Created a scalable integration model for future automation cells [More About Product](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/) [See More Results](https://www.caroneng.com/result/cnc-chip-overflow-prevention-miconnect/) [Download](https://www.caroneng.com/wp-content/uploads/78754_CNC-Chip-Overflow-Prevention_Manufacturing-1.pdf) ## TMAC Defect Detection --- ## [TMAC Detects Material Defect Mid-Cut—Preventing Tool Damage and Protecting Part Quality](https://www.caroneng.com/result/tmac-detects-material-defect-mid-cut-preventing-tool-damage-and-protecting-part-quality) # TMAC Detects Material Defect Mid-Cut—Preventing Tool Damage and Protecting Part Quality | | | | --- | --- | | **Industry:** | Precision Machining | | **Machine:** | Mill-Turn | | **Material:** | Hardened 4140 Steel | | **Tooling:** | End Mill | [![](https://www.caroneng.com/wp-content/uploads/TMAC_Logo-768x132.png)](https://www.caroneng.com/products/tmac/) ## Challenge During a machining operation on a 2.5″ 4140 steel bar, TMAC—a real-time tool monitoring and adaptive control system—issued an **undercut alarm**, signaling an unexpected drop in cutting load. The operator inspected the active tool and found no signs of wear or damage. The previously used tool was also in good condition, leaving the cause of the alarm unclear. Further investigation revealed the issue was not tooling—it was the material. A portion of the workpiece had fractured during machining due to a **void or inclusion running through the center of the bar**, creating a structural weakness that caused the part to break when the end mill engaged the edge. Without immediate intervention, subsequent tools would have continued machining a compromised part—risking tool breakage, scrap, and potential machine damage. ## Solution #### TMAC Response TMAC detected the abnormal cutting condition in real time and **automatically stopped the process**—preventing further damage before the next tool engaged. This response enabled the team to: - Prevent subsequent tools from engaging a fractured workpiece - Avoid tool damage, scrap escalation, and potential machine impact - Quickly determine the root cause as a material defect—not a tooling issue _TMAC monitoring showing successful cut within preset limits_ _TMAC monitoring showing undercut alarm that alerted the operator to find the corrupted bar_ #### The Results - **Prevented downstream tool damage** from machining a compromised part - **Contained a material defect** before it impacted additional production - **Isolated all parts** from the affected bar for inspection and validation - **Removed suspect material** from production immediately - **Protected customer quality** by preventing a potentially defective part from shipping - **Enabled supplier feedback** to address the material issue at its source #### The Value of Real-Time Process Monitoring Material defects are often invisible until failure occurs. By monitoring the cutting process in real time, TMAC detects abnormal conditions the moment they happen—and can automatically stop the machine to prevent escalation. In this case, TMAC not only protected tooling, but helped prevent a broader quality issue from reaching the customer. ### Results - Prevented downstream tool damage from compromised material - Contained the defect before impacting additional production - Isolated and removed all suspect material from the process - Protected part quality and enabled supplier corrective action Material inclusion revealed within 4140 steel bar after TMAC stopped the machine—preventing further tool damage and isolating defective parts. [More About Product](https://www.caroneng.com/products/tmac/) [See More Results](https://www.caroneng.com/results/?_sft_product=tmac) [Download](https://www.caroneng.com/wp-content/uploads/12353_TMAC-Detects-Material-Defect-Mid-Cut_Manufacturing.pdf) ## Caron Engineering Support --- ## [Product Support Request Form](https://www.caroneng.com/support) # Product Support Request Form - \\* Required Field - Name\* FirstLast - Phone\* - Email\* - Company\* - Problem Location's Address\* Street AddressAddress Line 2CityState / Province / RegionZIP / Postal CodeAfghanistanAlbaniaAlgeriaAmerican SamoaAndorraAngolaAnguillaAntarcticaAntigua and BarbudaArgentinaArmeniaArubaAustraliaAustriaAzerbaijanBahamasBahrainBangladeshBarbadosBelarusBelgiumBelizeBeninBermudaBhutanBoliviaBonaire, Sint Eustatius and SabaBosnia and HerzegovinaBotswanaBouvet IslandBrazilBritish Indian Ocean TerritoryBrunei DarussalamBulgariaBurkina FasoBurundiCabo VerdeCambodiaCameroonCanadaCayman IslandsCentral African RepublicChadChileChinaChristmas IslandCocos IslandsColombiaComorosCongoCongo, Democratic Republic of theCook IslandsCosta RicaCroatiaCubaCuraçaoCyprusCzechiaCôte d'IvoireDenmarkDjiboutiDominicaDominican RepublicEcuadorEgyptEl SalvadorEquatorial GuineaEritreaEstoniaEswatiniEthiopiaFalkland IslandsFaroe IslandsFijiFinlandFranceFrench GuianaFrench PolynesiaFrench Southern TerritoriesGabonGambiaGeorgiaGermanyGhanaGibraltarGreeceGreenlandGrenadaGuadeloupeGuamGuatemalaGuernseyGuineaGuinea-BissauGuyanaHaitiHeard Island and McDonald IslandsHoly SeeHondurasHong KongHungaryIcelandIndiaIndonesiaIranIraqIrelandIsle of ManIsraelItalyJamaicaJapanJerseyJordanKazakhstanKenyaKiribatiKorea, Democratic People's Republic ofKorea, Republic ofKuwaitKyrgyzstanLao People's Democratic RepublicLatviaLebanonLesothoLiberiaLibyaLiechtensteinLithuaniaLuxembourgMacaoMadagascarMalawiMalaysiaMaldivesMaliMaltaMarshall IslandsMartiniqueMauritaniaMauritiusMayotteMexicoMicronesiaMoldovaMonacoMongoliaMontenegroMontserratMoroccoMozambiqueMyanmarNamibiaNauruNepalNetherlandsNew CaledoniaNew ZealandNicaraguaNigerNigeriaNiueNorfolk IslandNorth MacedoniaNorthern Mariana IslandsNorwayOmanPakistanPalauPalestine, State ofPanamaPapua New GuineaParaguayPeruPhilippinesPitcairnPolandPortugalPuerto RicoQatarRomaniaRussian FederationRwandaRéunionSaint BarthélemySaint Helena, Ascension and Tristan da CunhaSaint Kitts and NevisSaint LuciaSaint MartinSaint Pierre and MiquelonSaint Vincent and the GrenadinesSamoaSan MarinoSao Tome and PrincipeSaudi ArabiaSenegalSerbiaSeychellesSierra LeoneSingaporeSint MaartenSlovakiaSloveniaSolomon IslandsSomaliaSouth AfricaSouth Georgia and the South Sandwich IslandsSouth SudanSpainSri LankaSudanSurinameSvalbard and Jan MayenSwedenSwitzerlandSyria Arab RepublicTaiwanTajikistanTanzania, the United Republic ofThailandTimor-LesteTogoTokelauTongaTrinidad and TobagoTunisiaTurkmenistanTurks and Caicos IslandsTuvaluTürkiyeUS Minor Outlying IslandsUgandaUkraineUnited Arab EmiratesUnited KingdomUnited StatesUruguayUzbekistanVanuatuVenezuelaViet NamVirgin Islands, BritishVirgin Islands, U.S.Wallis and FutunaWestern SaharaYemenZambiaZimbabweÅland IslandsCountry - Product:\* TMACAutoCompToolConnectDTect-ITSmart LightBlum LaserBlum ProbeRenishaw ProbeOther - Machine Model - Control Model - CEI Product Serial # - Please describe the issue\* - reCAPTCHA Recaptcha requires verification. I'm not a robot reCAPTCHA - Email Notifications ## CNC Machining Solutions --- ## [Advanced CNC Machining Products](https://www.caroneng.com/products) # Advanced CNC Machining Products Caron Engineering offers a unique line of CNC machining products and manufacturing technology that is extensive in its capabilities. The unique cutting edge solutions interface with nearly any CNC machine tool on the market, regardless of builder, with decades of proven success optimizing productivity across all manufacturing sectors. **MiConnect Technology** is a powerful application builder that enables seamless interconnectivity and control of your manufacturing environment—bridging CNC machines, robots, supervisory systems, and automation components to create a fully integrated and optimized production process. [Learn More](https://www.caroneng.com/miconnect-technology/ "Learn More") Tool Monitoring Adaptive Control measures tool wear in real-time and uses adaptive control to automatically optimize feed rates through variations in material cutting; to maximize tool life and reduce cycle time. [Learn More](https://www.caroneng.com/products/tmac/ "Learn More") Completely customizable industrial tool identification and data management system; automating the transfer of tool presetter data to (and from) the machine CNC control via RFID tags in tool holders or 2D barcodes. [Learn More](https://www.caroneng.com/products/toolconnect/ "Learn More") A PC-based software application that processes data from almost any electronic gauging device and automatically updates tool offsets in the CNC control. No manual data entry needed! [Learn More](https://www.caroneng.com/products/autocomp/ "Learn More") DTect-IT is a versatile CNC sensor analysis system that combines high precision sensor data with multiple analysis options to essentially monitor any area of concern on your CNC machine tool or fixture. [Learn More](https://www.caroneng.com/products/dtect-it/ "Learn More") Fully customizable status lights for easy assessment of a part's progress, or any machine status indication. [Learn More](https://www.caroneng.com/products/smart-light/ "Learn More") In-Process Measuring and Testing Technology [Learn More](https://www.caroneng.com/products/blum-novotest/ "Learn More") ## Measuring Technology Solutions --- ## [Blum-Novotest Distributor of In-Process Measuring & Testing Technology](https://www.caroneng.com/products/blum-novotest) # Blum-Novotest Distributor of In-Process Measuring & Testing Technology Caron Engineering is an authorized Blum-Novotest distributor and integrator of innovative and high-precision measuring and testing technology. With countless applications across dozens of industries, Blum-Novotest distributor Caron Engineering can provide globally recognized machine testing technology with hands-on integration support and exceptional customer service. As the distributor for the greater New England region of the United States, Caron Engineering is proud to offer this exceptional technology to the following states and regions: - Connecticut - Delaware - Maine - Maryland - Massachusetts - New Hampshire - New Jersey - Rhode Island - Vermont - Central & Eastern Regions of New York and Pennsylvania To request more information on how Caron Engineering can become your authorized Blum-Novotest distributor, please submit a form through [our contact page](https://www.caroneng.com/request-a-quote/) and we will be happy to help you find the right in-machine metrology solution for your manufacturing facility. [Have a question about Blum-Novotest products?](https://www.caroneng.com/contact/) ## Laser Measuring Systems As a Blum-Novotest distributor, Caron Engineering offers laser measuring systems for a non-contact-based tool setting solution inside the machine. These systems provide data that can be used to analyze tools of various shapes and sizes. As a tool enters the laser beam, these systems continuously measure the shading of the beam to gather data. Laser Measuring Systems provide: - Tool identification - Tool wear - Tool length and radius measurement - Single cutting-edge monitoring - Thermal compensation - Preventative maintenance information (spindle health, tool life, etc. [Vist the Blum website to learn more](https://info.blum-novotest.com/lasermeasuringsystems2) ## Tool Setters A contact based tool setting solution inside the machine. Tool Setters, also referred to as Setting Probes, provide simple tool geometry by measuring the tool’s length and/or radius offset, wear and/or breakage. Tool Setters provide: - Tool wear - Tool length and radius measurement - Tool breakage detection - Thermal compensation [Visit the Blum website to learn more](http://info.blum-novotest.com/toolsettingprobes2) ## Touch Probes Workpiece Touch Probes set workpiece origin and measure features on the machined part to verify if component dimensions are within tolerance. Touch Probes inspect the workpiece by touching the part in various predetermined locations based on the CNC program cycle. Also called Part Probes, they provide: - Part and fixture setup - Workpiece measurement - Thermal compensation - Tool wear compensation [Vist the Blum website to learn more](https://info.blum-novotest.com/lasermeasuringsystems2) ## DIGILOG Scanning Probes Instead of recording values based on various touches to the part, DIGILOG Scanning Probes from Blum-Novotest scans the part, recording a constant stream of data to create a comparative measurement between a master part and the workpiece. DIGILOG Scanning Probes provide: - Contour scan - Shape profile - Detection of part discontinuity [Visit the Blum website to learn more](http://info.blum-novotest.com/digilogtouchprobes2) ## Bore Gauges Bore Gauges are used to measure bore dimensions during mass production of serial workpieces. The device generates measurement data independent of the machine tool’s positioning, therefore it can also be mounted outside of the machine tool, on a robot arm (for example). Bore Gauges are most commonly used in the automotive industry, providing: - Diameter measurement - Position measurement - Roundness measurement - Cylindricity measurement - Concentricity measurement [Vist the Blum website to learn more](https://info.blum-novotest.com/lasermeasuringsystems2) ## Surface Roughness Gauges Similar to DIGILOG Scanning Probes, Surface Roughness Gauges inspect the surface finish of a workpiece using a pulling movement. This type of movement is used to measure the amount of deflection as it relates to the distance traveled to evaluate the surface finish of the part. Roughness Gauges provide: - Roughness and/or surface texture measurement [Visit the Blum website to learn more](http://info.blum-novotest.com/roughnessgauge2) ## Automated Tool Compensation --- ## [Automated Tool Wear Compensation Software](https://www.caroneng.com/products/autocomp) # Automated Tool Wear Compensation Software Manual tool wear offset calculations can introduce errors that compromise part quality, increase scrap rates, and lower production efficiency. Caron Engineering's **AutoComp** automated tool wear compensation software eliminates this risk by automatically calculating tool offset adjustments and sending real-time feedback directly to the CNC control—ensuring precise, seamless tool wear compensation without any operator intervention. ## Error-Free Tool Offset Control AutoComp is a Windows-based software solution that reads and processes part measurement data from virtually any electronic gauging device. It calculates the necessary tooling adjustments and automatically updates the CNC control offsets—eliminating manual data entry and reducing human error. With AutoComp, manufacturers can achieve a fully automated, closed-loop system with real-time feedback for consistent, high-quality machining results. [Have a question about AutoComp?](https://www.caroneng.com/contact/) ## How AutoComp Software Works See how AutoComp works with any electronic gauging device to provide automated and error-free tool offset control! 1. **Simplified Setup**: Input your part dimensions, tolerances, and compensation limits to create an AutoComp routine tailored to your needs. 2. **Automatic Tool Compensation**: AutoComp reads measurement data, compares it to user-defined feature limits, and calculates the necessary tooling adjustments. 3. **Seamless Integration**: AutoComp sends real-time offset data directly to the CNC control. ## Gauging Devices Use almost any electronic gauging device to provide dimensional measurements and the AutoComp automated tool wear compensation software will calculate the necessary tooling adjustments. - CMMs - Digital Tooling - Probes - Laser Micrometers - Vision Systems - Wireless Gauging Device - Gauge Fixtures with LVDTs Don’t see your device? Caron Engineering can write drivers to retrieve data from nearly any type/brand of electronic measurement equipment. [Contact us](https://www.caroneng.com/contact/) for more information. ## PartView - The PartView feature displays dimensional data superimposed on a picture of your part - JPG images can be labeled with each area of the part being measured for deviation - Operators can more easily identify which area of the part will be compensated ## Key Features of AutoComp Caron Engineering's AutoComp is a leading solution for automating tool compensation in CNC machining. AutoComp seamlessly integrates with measurement devices and CNC controls to provide real-time offset adjustments based on actual part measurements. Key features of AutoComp include: - **Real-Time Feedback:** Instantly detects deviations and adjusts offsets to maintain consistent quality. - **Closed-Loop Machining:** Automatically compensates for tool wear, thermal growth, and other production variables. - **Error-Free Manufacturing:** Eliminates manual data entry, improving part quality and reducing scrap. - **Historical Reporting:** Compiles and reports tool wear measurements over time for process optimization. - **Tool Change Notifications:** Alerts operators when tools need replacement. - **MTConnect Compliant:** Enables real-time data sharing with supervisory software. ## Learn More About AutoComp Automating tool compensation is a game-changer for CNC machining, offering significant improvements in accuracy, efficiency, and cost savings. By leveraging solutions like AutoComp, manufacturers can achieve higher productivity while maintaining the strict tolerances required in modern machining. Are you ready to enhance your CNC machining process with automated tool wear compensation? [Contact us](https://www.caroneng.com/robotics-integration-cnc-machining/) today or explore the resources below to learn more about how AutoComp can optimize your operations. ## Bar Feeder Vibration Detection --- ## [CNC Bar Feeder Vibration Monitoring](https://www.caroneng.com/bar-feeder-vibration-detection) # CNC Bar Feeder Vibration Monitoring \| Prevent Downtime & Damage In the precision-driven world of CNC machining, automating the process of loading material into the CNC lathe is a critical automation component. However, automation without real-time control can create a lot of scrap very quickly. When imperfections in bar stock lead to increased vibration, the effects are often unnoticed until they result in scrap on the other end. Increased vibrations can lead to dimensional inaccuracies, compromised surface finishes, and increased machine wear—resulting in costly downtime and inefficiencies. CNC manufacturers frequently encounter these common bar feeder issues: - **Material Imperfections:** Irregularities in bar stock, such as bends or inconsistencies in composition, can result in excessive scrap and potential machine and spindle damage. - **Excessive Vibration:** Unwanted movement can reduce part quality and accelerate machine wear, leading to unplanned maintenance and downtime. - **Alignment Problems:** Misalignment between the bar feeder and lathe spindle increases stress on machine components, causing inefficiencies and potential equipment failure. ## Real-Time Bar Feeder Vibration Monitoring for CNC Stability [**DTect-IT**](https://www.caroneng.com/products/dtect-it/) offers an advanced, real-time solution to bar feeder vibration by continuously monitoring spindle vibration and responding instantly to abnormal conditions—before they impact part quality or machine health. The system integrates a high-resolution vibration sensor mounted on the main spindle to monitor vibration signals in real time during cutting. When vibration levels exceed the defined limits for producing good parts, DTect-IT automatically takes corrective action to stabilize the process and prevent damage and downtime. ## How It Works to Correct Bar Feeder Vibration When the DTect-IT bar feeder vibration monitoring system registers vibration levels that exceed acceptable cutting parameters, it signals the CNC to automatically reduce spindle RPM in real time—adjusting in defined increments—until vibration falls within an acceptable, user-defined, range to cut good parts. This allows machining to continue within tolerance, with vibration correction handled entirely automatically. If a significant vibration spike occurs that cannot be corrected through RPM adjustments, DTect-IT will signal the CNC to stop the process, preventing damage and scrap. This early detection and automatic correction help prevent costly spindle and machine damage, while also avoiding excessive scrap from running an entire bar of bent or imperfect stock that would otherwise go unnoticed. [How DTect-IT Fixes Bar Feeder Vibration with Automatic RPM Control](https://www.youtube.com/watch?v=nRzQYhoT_zk) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=nRzQYhoT_zk) _This video shows how DTect-IT reacts to a vibration warning to automatically adjust the spindle RPM to regulate vibration at the cutting zone._ - **Customizable Vibration Thresholds:** Operators can define vibration limits, triggering alerts or corrective actions when needed. - **Automated Spindle Adjustments:** When vibrations exceed acceptable levels, DTect-IT can automatically adjust spindle RPM to maintain machining stability. - **Data Logging and Analysis:** The system records vibration trends over time, offering valuable insights for predictive maintenance and process optimization. - **Seamless Integration:** Designed for compatibility with various CNC machines and bar feeder systems, DTect-IT enhances efficiency with flexible deployment options. [Request a Quote](https://www.caroneng.com/request-a-quote/ "Request a Quote") ## The Benefits of Implementing Bar Feeder Vibration Detection - **Enhanced Part Quality:** Detecting and mitigating excessive vibrations ensures superior surface finishes and consistent dimensional accuracy. - **Reduced Scrap Rates:** Early detection of material imperfections minimizes waste and lowers production costs. - **Extended Machine Life:** Maintaining optimal vibration levels reduces stress on critical components, prolonging equipment lifespan and reducing maintenance expenses. - **Increased Operational Efficiency:** Real-time monitoring and automatic adjustments enable smooth, high-performance machining, boosting productivity and profitability. [How DTect-IT Minimizes Scrap by Detecting Bar Feeder Vibration Early \| Product Demo](https://www.youtube.com/watch?v=yjXNlrF9j94) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=yjXNlrF9j94) _See how [Wolfram Manufacturing](https://wolframmfg.com/) is using the DTect-IT Bar Feeder Vibration Detection System to reduce scrap and spindle damage on a Swiss machining cell._ ## DTect-IT –– A Complete Sensor Analysis System The capabilities of [DTect-IT](https://www.caroneng.com/products/dtect-it/) span more than just a bar feeder vibration detection tool—it's a comprehensive CNC sensor analysis system capable of monitoring and analyzing data from a wide variety of sensors. Whether it's vibration, strain, power, analog, metrology signals—DTect-IT can integrate with compatible sensors to monitor and detect anomalies in a machining process. This multi-sensor capability allows manufacturers to gain real-time insight into their processes, enabling predictive maintenance, improving part quality, and enhancing overall machining efficiency. ### Why Choose DTect-IT? - **Proven Reliability:** Trusted by manufacturers to optimize machining performance and safeguard investments. - **User-Friendly Interface:** The intuitive software simplifies setup, monitoring, and data analysis with minimal training. - **Comprehensive Support:** Backed by [Caron Engineering’s](https://www.caroneng.com/) industry expertise, DTect-IT comes with robust customer support for seamless implementation and ongoing success. [Contact Us to Learn More](https://www.caroneng.com/contact/ "Contact Us to Learn More") ## Related Products ### CNC Sensor Analysis System ### Streamlined Process Automation Software ### Adaptive Tool Monitoring System ## TMAC AI Solutions --- ## [Real-Time Tool Monitoring Meets Predictive Analytics](https://www.caroneng.com/tmac-ai) # Real-Time Tool Monitoring Meets Predictive Analytics **TMAC ai™** , a collaboration between production monitoring leader, **[Datanomix](https://datanomix.io/?hsa_acc=2079907119&hsa_cam=22069154848&hsa_grp=1313918848072545&hsa_ad&hsa_src=o&hsa_tgt=kwd-82121135179736%3Aloc-190&hsa_kw=Datanomix&hsa_mt=p&hsa_net=adwords&hsa_ver=3),** and **Caron Engineering**, transforms real-time cutting data into actionable, predictive intelligence. Built on [**Caron Engineering’s leading Tool Monitoring Adaptive Control System (TMAC)**](https://www.caroneng.com/products/tmac/), TMAC ai™ continuously analyzes sensor data from each cut, generating adaptive models that pinpoint out-of-tolerance conditions with exceptional precision—turning every cut into insight that enhances tool performance, process control, and part quality. This predictive capability allows manufacturers to act instantly—reducing scrap, avoiding costly downtime, and ensuring tools and machines run at peak performance. From **automated limit setting** that evolves from initial startup to long-term AI-optimized thresholds, to **real-time process control** that flags suspect parts as they occur, TMAC ai™ empowers manufacturers to maintain stability, consistency, and efficiency across every operation. ## Limit Advisor - Automated Limit Setting with TMAC TMAC ai’s **Limit Advisor** automatically calculates optimal tool wear limits in TMAC based on **peak limits and cutting workload**, continuously recommending limit adjustments from real-time data. It adapts based on data history, from **Initial Limits** for new deployments, to **Interim Limits** as parts are processed, and finally to **Complete AI-Based** Limits using historical data for advanced predictive recommendations. Auto mode can update limits directly in the TMAC system as data evolves, while manual mode provides actionable recommendations for human review. **For Existing TMAC Customers**: - Accelerates TMAC setup on new products and processes - Quickly recalculates limits when introducing new materials - Makes it easy for new engineers to get value from TMAC immediately **For New TMAC Customers**: - Speeds time-to-value by eliminating manual limit setup - Provides accurate limits from the very first cuts - Reduces reliance on specialized process knowledge ## Total Process Control with Suspect Parts Review The **Suspect Parts Review** feature in **TMAC ai™** continuously analyzes TMAC cutting data to detect anomalies and flag potential issues _before they impact part quality._ Caron Engineering’s [**TMAC**](https://www.caroneng.com/products/tmac/) system measures spindle power in real time during cutting, while **TMAC ai™** analyzes this data to establish a **gold-standard process signature**—the ideal cutting profile for a quality part. Using this baseline, TMAC ai defines a **dynamic “blue band” of acceptable variation**. Any cycle that deviates beyond this range is automatically flagged as a suspect part, providing **immediate visibility into process instability** before it affects downstream operations. This capability allows teams to quickly identify [root causes, reduce scrap and rework, and maintain consistent part quality.](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/) It identifies quality issues **as they happen—without halting production**, and isolates suspect parts that can be **traced back at any time for warranty or quality verification**. The intuitive visual interface makes it easy to see deviations at a glance, helping users make fast, confident decisions to keep production running smoothly. ## Real-Time Insights for Smarter Tool Life Management **TMAC ai™** continuously analyzes real-time cutting data to deliver **intelligent insights and recommendations for tool usage**. It identifies when machining processes are stable or tools are being expired too early in TMAC—allowing tool limits to be safely extended—and when wear or instability signals the need for replacement. This adaptive approach ensures every tool is used to its full potential, reducing costs, maintaining part quality, and maximizing overall performance. Traditionally, manufacturers have relied on conservative, OEM-recommended tool life estimates. With **TMAC**, they can monitor tool wear precisely in real time—and with **TMAC ai™**, pinpoint the exact moment a tool begins to impact part quality. TMAC ai’s advanced tool-life analytics provide actionable insights to compare performance across vendors, validate process changes, and uncover inconsistencies in tooling that may be affecting quality and profitability. **Together, TMAC and TMAC ai™ empower manufacturers to achieve the maximum life from every cutting tool—optimizing productivity, reducing waste, and driving measurable cost savings.** [Have a question about TMAC ai?](https://www.caroneng.com/contact/) ## Combined Power of TMAC + TMAC ai™ Every second counts in high-production manufacturing. **TMAC** and **TMAC ai™** work together to transform your machining data into actionable intelligence—helping you make faster, smarter decisions that directly impact quality, efficiency, and profitability. #### **🛠️ Protect Product Quality** With **Predictive Quality Feedback**, TMAC ai™ analyzes every cut in real time to detect anomalies that could affect dimensional accuracy or surface finish. By flagging suspect parts during the machining process, operators can make immediate corrections instead of discovering issues later in inspection—reducing scrap, rework, and costly downtime. #### **⚙️ Maximize Tool Investment** **Tool Life Optimization** ensures every tool is used to its full potential. By analyzing real-time cutting conditions, TMAC ai™ identifies when tools can safely run longer to reduce replacement costs—or when early wear may compromise part quality. This balance between productivity and protection extends tool life and maintains consistent results across shifts. #### **➡️ Accelerate TMAC Setup** **Automated Limit Setting** eliminates manual setup by using live cutting data to calculate and recommend optimal process limits automatically—accelerating system deployment. For TMAC users, this means **faster time-to-value**—ensuring your processes are always running at peak efficiency from the first part to the last. A leading precision components manufacturer uses TMAC ai to access more advanced process intelligence across automated machining cells. TMAC ai enables **real-time detection of suspect parts and faster root-cause analysis** that protects quality, reduces scrap, and maximizes productivity. [Click here](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/) to learn more about TMAC ai in action... [Read the Latest Customer Success with TMAC ai](https://www.caroneng.com/result/tmacai-empowers-predictive-quality-for-precision-manufacturing/) [IMTS Partner Interviews Caron Engineering](https://www.youtube.com/watch?v=-ZoAc2ZqXGI) [Datanomix](https://www.youtube.com/channel/UCPXPw64xHx3cZXZGJgpnUSA) [Watch on](https://www.youtube.com/watch?v=-ZoAc2ZqXGI) _Rob Caron, Founder and CEO of Caron Engineering, interviews with MTD CNC at IMTS 2024 in the Datanomix booth to introduce TMAC ai._ ## The Collaboration Behind TMAC ai™ By applying real-time predictive insights, TMAC ai empowers manufacturers to take control of their processes like never before. Whether it's catching out-of-tolerance parts before they affect production, optimizing tool usage, or shortening cycle times, TMAC ai delivers the advanced analytics needed to stay competitive and efficient. ## Related Products ### Adaptive Tool Monitoring System ### Streamlined Process Automation Software ### Automated CNC Offset Control Software ## Careers at Caron Engineering --- ## [Careers at Caron Engineering](https://www.caroneng.com/careers) # Careers at Caron Engineering At Caron Engineering, we are an employee-owned company (ESOP). We pride ourselves on our open and transparent culture that allows employees to see how their work contributes to the overall success of the company. Our employees are our most valuable assets, and we’re committed to providing a positive work environment that promotes teamwork and career advancement opportunities. We believe in building strong relationships with each other, our customers, and the community. We are a company that specializes in automation, monitoring, and process control technology for manufacturing. Our goal is to help our customers improve their manufacturing process by providing them with the tools and knowledge necessary for them to succeed. We believe that every customer deserves the best possible product, which is why we strive for continuous improvement through innovation. We believe in our mission, and we are proud to say that it has led us to become one of the most trusted names in manufacturing technology. To learn more about Caron Engineering, check out this company video! ## Interested in Joining Our Team? We are seeking a full-time Shipping-Receiving / Shop Assistant who would be responsible for shipping and receiving, inventory management, and shop maintenance. [Apply on Indeed](https://www.indeed.com/job/shipping-receiving-shop-assistant-b1fb1c594dc06abb) We are seeking a full-time Service Technician who would be responsible for assembling, installing, and field testing our products based on our customers' requirements. [Contact Us to Apply Today](https://www.caroneng.com/contact/) [![](https://www.caroneng.com/wp-content/plugins/bb-plugin/img/pixel.png)](https://www.indeed.com/job/service-technician-20-maine-80-travel-ny-nj-new-england-5634373ddbddacb5) ## More About Caron Engineering ### About Caron Engineering ### Technology Partners ### Clients and Industries ## Closed Loop Machining Solutions --- ## [Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets](https://www.caroneng.com/closed-loop-machining-electronic-gauging-and-automated-tool-offset-control) # Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets In today’s high-precision manufacturing world, **tool wear isn’t a question of if—it’s a question of when**. Whether you’re cutting aluminum or Inconel, compensating for dimensional drift is essential to ensure consistent quality and protect profit margins. Most manufacturers already use **electronic gauging systems** to measure critical part dimensions. From **CMMs and vision systems to laser scanners,** **blue tooth calipers, and LVDTs**, dimensional feedback is everywhere. But for many shops, that insight stops at the screen—it’s reviewed, recorded… and then manually entered into the CNC control. That’s where errors creep in. That’s where time is lost. And for operations moving toward **fully automated** **production**, this missing link— **closed-loop feedback**—is a critical gap. So, what if those measurement devices didn’t just tell you what needed to be corrected—but actually **made the adjustments automatically**? ## From Measurement to Machining Correction That’s exactly what [AutoComp](https://www.caroneng.com/products/autocomp/) was built to do. AutoComp is a **platform-agnostic software solution** that turns any compatible electronic gauging system into an **active part of your CNC machining** **process**. It analyzes measurement data in real-time, compares it to user-defined tolerance limits, determines if a compensation is needed, and automatically applies the correction to the CNC— **no manual input, no operator guesswork**. It doesn’t matter if you’re running a brand-new 5-axis machine or a 20-year-old lathe—AutoComp interfaces with **virtually any CNC control**, acting as the bridge between inspection data and machining correction. All of this is configured through a **user-friendly interface** that lets you define how offsets are applied per feature, per tool, or per machine. As your processes evolve, AutoComp evolves with them. ## Closed Loop Manufacturing - Why It Matters Relying on manual offset entry introduces **delay, human error, and inconsistency**. Meanwhile, **offline measurement data** that isn’t acted on in real time loses its value. By automating the feedback loop, AutoComp helps you: - **Prevent scrap** by applying offsets before out-of-tolerance parts are made - **Support lights-out operations** with closed-loop process control - **Shorten cycle times** by eliminating manual quality checks and data entry - **Ensure consistency** from shift to shift and machine to machine In short: AutoComp makes your data **actionable**, closing the loop between **inspection and correction**. ## Build an Intelligent, Connected Workflow Whether you’re a **job shop with standalone gauges** or a **high-volume facility running robots and CMMs**, AutoComp makes it possible to build **smart, scalable manufacturing processes** that adapt in real time. You already have the measurement data. Now it’s time to put it to work. ## Ready to Close the Loop? Visit [caroneng.com](https://caroneng.com/) or [contact us](https://www.caroneng.com/contact/) to talk to our automation specialists about how **AutoComp** can integrate with the systems you already use— **gauges, scanners, probes, CMMs, vision systems**, and more. Let’s move from inspection… to **correction. Automatically.** ## Related Products ### Adaptive Tool Monitoring System ### Automated CNC Offset Control Software ### Streamlined Process Automation Software ## Caron Engineering Brochures --- ## [Caron Engineering Brochures](https://www.caroneng.com/resources/brochures) # Caron Engineering Brochures Caron Engineering Company Brochure ## Downloads by Product - [TMAC Brochure](https://www.caroneng.com/wp-content/uploads/TMAC-Brochure-V02.2026.pdf) - [ToolConnect Brochure](https://www.caroneng.com/wp-content/uploads/ToolConnect-Brochure-2026.pdf) - [ToolConnect Barcode ID Flyer](https://www.caroneng.com/wp-content/uploads/ToolConnect-Barcode-ID-Flyer.pdf) - [AutoComp Brochure](https://www.caroneng.com/wp-content/uploads/AutoComp-Brochure-V06.2021.pdf) - [AutoComp Flyer](https://www.caroneng.com/wp-content/uploads/AutoComp-Flyer_Caron-Engineering.pdf) - [Variable Data Collect](https://www.caroneng.com/wp-content/uploads/Variable-Data-Collect-App_Caron-Engineering.pdf) - [DTect-IT Brochure](https://www.caroneng.com/wp-content/uploads/DTect-IT-Brochure-2026.pdf) - [CEI Smart Light Brochure](https://www.caroneng.com/wp-content/uploads/Smart-Light-Brochure-2026.pdf) - [MiConnect Brochure](https://www.caroneng.com/wp-content/uploads/MiConnect-Brochure-2026.pdf) - [Blum-Novotest Catalog](https://www.caroneng.com/wp-content/uploads/Blum-Novotest-Product-Catalog.pdf) ## CNC Smart Light --- ## [Customizable CNC Machine Status Light](https://www.caroneng.com/products/smart-light) # Customizable CNC Machine Status Light Caron Engineering's customizable CNC machine status Smart Light System provides an easy assessment of a part's progress on a CNC program. A standard machine status light, or stack light, is used in an industrial manufacturing or process control environment to deliver real-time visual feedback to machine operators, technicians, production managers, and other factory personnel. While traditional stack lights have limited indicators showing basic machine status, the Smart Light offers over 1000 LED light configurations that can be custom-programmed for any machine status or condition indication. With intuitive operator screens, the user can preconfigure recipes for basic light outputs, or use direct set protocol for advanced control of the light stack to dynamically change the light to correspond directly to an extensive number of manufacturing steps. [Have a question about the CEI Smart Light System?](https://www.caroneng.com/contact/) ## Smart Light System Features See how the CNC Machine Smart Light System can be customized to optimize productivity at your shop! - 1000 available modes, 0-255 available via direct I/O - 6 different colors (white, green, blue, yellow, red, orange), plus one (1) user-defined color - Use multiple protocols at the same time - Lights can be mounted/installed anywhere on the machine - Can directly replace existing status light - Lights can be in "Steady State", "Blinking", "Flashing" or all 3 at the same time - Programmable audible alarm ## Light Modes The CEI Smart Light System offers a variety of modes and color options for any status indication. Modes include: Single Color, Level Mode, Segment Mode, and Run Light Mode. The status lights can be in Steady State, Blinking, Flashing, or a combination of all three at the same time. With a seemingly endless combination of color configurations and programmable buzzer tones, any machine status can be easily conveyed to operators from a distance, reducing the need for continual hands-on inspection that requires additional personnel and time. _**LED Smart Lights can be programmed to display unique colors, patterns, or color combinations to reflect the below statuses and countless other industry or machine specific scenarios not mentioned:**_ - Machine warmup state - Transitional states - Process or stage time remaining - The machine requires attention from an operator - Tool wear conditions are present - Laser measurement is in progress or has been completed - Machining is complete - Countdown timers - The machine requires additional supply (i.e. bar feeder is on the last bar) - ![SL Solid Color Caron Engineering](https://www.caroneng.com/wp-content/uploads/SL-Solid-Color_Caron-Engineering.png) SINGLE COLOR - Lights can be any color and can be solid, blink, or flash - Can replace existing status light - ![SL Level Mode Caron Engineering](https://www.caroneng.com/wp-content/uploads/SL-Level-Mode_Caron-Engineering.png) LEVEL - 1 – 20 lights lit in succession and can be any solid color - Used to indicate cycle status (%) or any level - ![Smart Light Modes_Caron Engineering](https://www.caroneng.com/wp-content/uploads/SL-Segment-Mode_Caron-Engineering.png) SEGMENT - Up to 5 light segments - Segments can be any color and be solid, blink, or flash - ![SL Run Light Mode Caron Engineering](https://www.caroneng.com/wp-content/uploads/SL-Run-Light-Mode_Caron-Engineering.png) RUN LIGHT - Any foreground color can run over any background color - 1 – 3 segments can be running. - Used for special indications ## Configuration Software **RECIPE BUILDER** - Builds system configuration with custom modes and communication protocols - Custom recipes are created to control the light by calls from the CNC program **LIVE DEMO MODE** - Used for testing all light configurations before programming recipes All Caron Engineering products include the MTConnect protocol communications which allows us to provide meaningful data to any supervisory software, for real-time data sharing. ## CNC Automation Platform --- ## [Low-Code CNC Automation Platform for Manufacturing Integration](https://www.caroneng.com/miconnect-technology) # Low-Code CNC Automation Platform for Manufacturing Integration **MiConnect** is a low-code CNC automation and manufacturing integration platform that allows engineers to build automation applications in a fraction of the time required for traditional development. Designed specifically for manufacturing environments, MiConnect connects CNC machines, robots, gauging systems, sensors, and factory software into unified automation workflows — without custom programming. Modern factories rely on a wide range of machines, devices, and systems that must work together. Traditionally, integrating these technologies requires complex coding, long development cycles, and rigid infrastructure. MiConnect eliminates that complexity through a **visual application builder and prebuilt device integrations**, enabling manufacturers to rapidly automate workflows, reduce errors, and adapt processes at any time. [Have a question about MiConnect Technology?](https://www.caroneng.com/contact/) ## Build CNC Automation Applications Without Coding Custom automation projects have historically required months of programming, testing, and deployment. _**MiConnect changes that.**_ Using its low-code application builder, manufacturers can build and deploy automation workflows in **days, hours, or even minutes instead of months**. MiConnect provides a **visual, flowchart-based application builder** (editor) that allows manufacturers to connect devices, configure logic, and automate workflows without traditional programming. Using a drag-and-drop interface and prebuilt integrations, engineers can rapidly design, deploy, and modify automation applications that connect machines, systems, and processes across the shop floor. **Connect Machines and Devices** MiConnect integrates CNC machines, robots, gauging systems, sensors, and software platforms using prebuilt communication drivers and plugins. **Configure Automation Logic** Engineers define workflows using drag-and-drop logic blocks, creating automation rules based on machine states, sensor inputs, or operator actions. **Control Process Flow and Operator Interaction** MiConnect guides operators through step-by-step workflows, ensuring processes are followed correctly and consistently. Progression control holds the process at critical steps until required actions are completed, reducing risk and reinforcing compliance. **Trigger Automated Actions** MiConnect executes automation workflows in real time — loading programs, transferring data, guiding operators, or controlling equipment automatically. [Download the Brochure](https://www.caroneng.com/wp-content/uploads/MiConnect-Brochure-2026.pdf) ## Connect Machines, Devices, and Factory Systems Manufacturing environments can be complex — with multiple machine types, integrated automation devices, and a variety of software systems operating together. MiConnect removes the complexity as a **manufacturing integration platform**, enabling communication and control between: - CNC machines and controls - robots and automation cells - gauging and inspection systems - RFID and barcode systems - PLCs and industrial I/O - MES, ERP, and databases Every production process is unique, and MiConnect is a flexible platform that can scale with your operations. MiConnect has an extensive library of **prebuilt integrations**, which eliminates the need for custom interface development and allows manufacturers to connect systems quickly and efficiently. ## Solve Small Manufacturing Problems — or Automate Entire Systems Not every automation project needs to be complex. Many of the most valuable improvements come from solving **simple, error-prone processes**. MiConnect supports both. MiConnect can be configured for **a single task or an entire factory environment**, giving manufacturers complete flexibility. ### ⚙️ Simple Automation Applications - Scan a **barcode to automatically load CNC programs** - Transfer a **single piece of production data between systems** - Verify **tooling or setup conditions** - Trigger **alerts or operator prompts** ### ⚙️ Advanced Automation Systems - End-to-end **automated production cells** - Real-time **machine-to-machine data interchange** - **Supervisory control** and automation orchestration - Unattended, **lights-out manufacturing** operations ### Flexible and Fully Customizable MiConnect applications are fully adaptable to each manufacturing environment, supporting everything from simple automation tasks to complex, multi-system workflows. The platform can operate in fully automated modes or incorporate manual inputs where required, providing flexibility without sacrificing control. By combining device integration, visual logic design, and real-time execution, MiConnect enables manufacturers to build automation applications faster, reduce errors, and maintain consistent, reliable production processes. ## Prebuilt Device Integrations Accelerate Automation MiConnect simplifies connecting equipment and systems through a **library of prebuilt manufacturing device drivers and communication protocols**. **These integrations allow manufacturers to:** rapidly connect new equipment, automate communication between systems, eliminate manual data transfer, and standardize automation across the shop floor. The result is faster deployment and reduced engineering effort. **The growing inventory of pre-built device plugins include:** **Bluetooth Low Energy**: Used for sending and receiving data through Bluetooth Low Energy peripherals. **Ethernet/IP Scanner**: Initiates data exchange with other devices using the Ethernet/IP protocol. **Notifications**: Allows for notifications to be sent to external applications. **Serial Port:** Serial port connection used for sending and receiving data through a serial port. **Modbus**: Allows for data exchange to a Modbus TCP peripheral. **Zebra Scanner**: Connects directly to a Zebra Scanner device utilizing the SNAPI scanner API. **MQTT**: Create an MQTT client to Publish/Subscribe to Topics from a Broker. **TCP/IP**: Create a TCP/IP connection to a remote host. **Data Compensation**: Processes measured data against a nominal measurement, tolerance limits, and compensation limits. **File**: Generic plugin for processing files and directories. **REST API**: Perform requests to an external REST API and automatically parse the results. **System API**: Adds various operating system related functionality to the project. **I/O Interface**: Connect to various types of peripheral I/O devices to read inputs and control outputs. **CNC Machine**: CNC interface for interacting with various types of CNC machines. **RFID Reader**: RFID Reader adapter used for reading and writing RFID chips using containing tool information. **OPC UA**: Allows MiConnect to act as an OPC UA server or client for devices that communicate with OPC UA protocol. **SQL Connection**: Connect to one or more databases on a SQL server. ## Guide, Validate, and Monitor with Custom User Screens The MiConnect "run time" user interface delivers **customizable screens** that support real-time operation and interaction on the shop floor. With message screens, status displays, and user prompts, MiConnect provides the flexibility to **guide operators** through workflows, capture critical inputs, and display real-time process information. These interfaces **ensure consistent execution**, improve visibility, and enable reliable automation — whether processes are fully automated or operator-driven. MESSAGE SCREENS Message screens can be used to display any essential notifications or alerts to inform the user of important process steps, confirmations, or errors during the process. STATUS SCREENS Status screens offer a real-time overview of the system’s operational status, allowing the user to monitor performance, activity levels, and any ongoing processes at a glance. USER PROMPTS These interactive screens guide the operator by requesting input or confirmation to proceed with specific actions, ensuring controlled and accurate operation within the manufacturing process. ## How Can We Apply MiConnect Technology to Your Operations? ### Automation Cell Orchestration Coordinate and control device communication between CNC machines, [robots and machine tending integration](https://www.caroneng.com/robotics-integration-cnc-machining/), and auxiliary equipment — ensuring synchronized, efficient operation across the manufacturing environment. ### Connected Input Automation Use RFID, barcode, files, and network inputs to trigger workflows, automatically load part programs, input job information, parse data, and initiate automation processes. ### Data Bridge and Interchange Seamlessly exchange and act on production data between CNC machines, robots, PLCs, sensors, and manufacturing systems such as MES, ERP, and databases. _Reads and writes any system parameters, variables, offsets, and PLC registers._ ### User Authentication and Access Control [Control machine and system access using RFID badges or credentials](https://www.caroneng.com/rfid-operator-authentication/), enforce training requirements, and ensure only qualified personnel perform specific operations. ### Sensor-Driven Automation Monitor real-time conditions and trigger automated actions based on machine states, sensor inputs, and production events to maintain process control and prevent issues. ### Operator Guidance and Error-Proofing Guide operators through step-by-step workflows, verify task completion, and enforce process consistency, to eliminate error and increase productivity. ## Fully Customizable — Adapt at Any Time Manufacturing processes are constantly evolving, requiring automation systems that can adapt just as quickly. MiConnect was designed with a **flexible architecture** that allows automation workflows to be modified, expanded, or reconfigured at any time — **without the need for reprogramming.** This enables manufacturers to seamlessly adapt to new parts and processes, integrate additional machines or devices, update workflows without disrupting production, and scale automation across the entire facility. Unlike traditional automation systems that can become rigid over time, **MiConnect evolves alongside your production environment**, supporting continuous improvement and long-term flexibility. Benefits Features Audit Log Benefits - Eliminates data entry and process errors - Automates communication to the CNC control - Reduces setup time and streamlines process execution - Controls discrete devices via digital I/O - Creates user defined checks and balances - Minimizes operator decision making and adds system securities - Provides consistent and accurate control of your manufacturing processes Features - Seamlessly connects devices and operations - Flexible for any application, and connects to almost any machine/control type - Process flow is customized to the users' specifications - Guides user through required steps and confirms successful execution - Can easily be upgraded with new features - All steps and data are recorded in the Audit Log and available via MTConnect Audit Log - Every step, action and data exchange is logged with date and time stamp - Data is available locally or via MTConnect - The data is valuable for quality control and process verification [MiConnect: Automation Cell Controller in Action \| Caron Engineering](https://www.youtube.com/watch?v=d6G1rR6dWcE) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=d6G1rR6dWcE) Video: MiConnect Technology powers all inter-device communication in this fully automated CNC manufacturing production cell. ## Let Us Design Your Custom MiConnect Application Caron Engineering has a long history of integrating technology across all CNC machine and control types. Leveraging advanced interfacing and control capabilities, **MiConnect** provides a flexible foundation for customized automation solutions tailored to each customer’s environment. [CONTACT US!](https://www.caroneng.com/contact/) ## Products Powered by MiConnect Technology [![Tool Connect logo](https://www.caroneng.com/wp-content/uploads/Tool-Connect-Color-match-300x93.png)](https://www.caroneng.com/products/toolconnect/) [![Machine Tending Integration Logo_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Machine-Tending-Integration-Logo_Caron-Engineering-300x117.png)](https://www.caroneng.com/machine-tending-integration/) [![RFID Operator Authentication Logo_Caron Engineering](https://www.caroneng.com/wp-content/uploads/RFID-Operator-Authentication-Logo_Caron-Engineering-300x117.png)](https://www.caroneng.com/rfid-operator-authentication/) ## Videos — MiConnect Technology [MiConnect Technology: Simplifying Manufacturing Automation \| Product Introduction](https://www.youtube.com/watch?v=z50v9qlUyQg) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=z50v9qlUyQg) [How MiConnect Automates CNC Part Program Loading from QR Scan](https://www.youtube.com/watch?v=vjJFjIR77kc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=vjJFjIR77kc) [RFID User Authentication: Enhancing Manufacturing Security \| Caron Engineering](https://www.youtube.com/watch?v=l_lVU70P0F0) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=l_lVU70P0F0) ## MiConnect FAQs - CNC Automation Integration What is a low-code CNC automation platform? A low-code platform allows users to build automation workflows using visual tools instead of traditional programming, reducing development time and complexity. Can MiConnect integrate with any CNC machine and control type? Yes. Just like all Caron Engineering products, MiConnect can integrate across different CNC and control types, regardless of builder. MiConnect connects CNC machines, robots, sensors, gauges, and software platforms into a unified automation environment. Does MiConnect require programming? No. MiConnect uses a visual application builder with prebuilt integrations, eliminating the need for custom coding. However, MiConnect does allow the ability to create custom function blocks using JavaScript or TypeScript. Can MiConnect be customized as production requirements change? Yes. MiConnect is fully customizable and can be easily modified to match changing production requirements. Modify workflows, add devices, or change logic at any time, without rewriting software or redeploying applications. ## Seamless Machine Communication --- ## [The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)](https://www.caroneng.com/the-missing-link-in-automation-how-to-get-your-machines-talking-without-the-headaches) # The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches) For many manufacturers, the promise of automation is clear: increased productivity, reduced downtime, and more consistent quality. But making that promise a reality? That’s where things can get complicated. One of the biggest challenges in **CNC automation integration** is getting all your machines, devices, and systems to communicate with each other. Different machines. Different controllers. Different software. All speaking different “languages.” It’s no wonder automation efforts often stall before they ever really get off the ground. If you’ve invested in robots, sensors, and automation equipment, but still find yourself relying on spreadsheets or manual operator input, you’re not alone. **Disconnected systems are the silent killers of productivity**, making it difficult to scale automation or become a true connected factory. The question isn’t whether automation is worth it. The question is: **_How do you get your automation systems working together seamlessly, without expensive custom software or complicated workarounds?_** ## The Integration Challenge Without proper integration between machines, devices, and software, manufacturers face a familiar set of obstacles. Manual data entry becomes a daily struggle, introducing errors and delays into the process. Automation cells operate in isolation, unable to share critical information with the CNC machines they support without significant programming time and potentially incorporating multiple different connections and software integration systems. Valuable process data—collected by sensors or measurement devices—often goes unused because it can’t be easily fed back to the machine to make real-time adjustments. These disconnects slow down progress, limit productivity, and frustrate the very people automation is meant to help. But integration doesn’t have to be complicated. **What if there was a way to bridge that gap and bring all your technology together under one intelligent interface?** ## Bridging the Gap with MiConnect At [Caron Engineering](https://www.caroneng.com/), we saw this problem firsthand in manufacturing environments of all sizes. That’s why we developed [**MiConnect**](https://www.caroneng.com/miconnect-technology/)—a customizable, flexible application builder designed to simplify data integration, device communication, and control across the shop floor. MiConnect provides a single, unified interface for communication between your CNC machines, automation equipment, robots, sensors, measurement devices, and manufacturing software systems. Regardless of machine type or control platform, MiConnect acts as the data bridge, bringing order to what often feels like chaos. More importantly, MiConnect isn’t just about making data visible—it’s about making it **actionable**. It provides access to all control registers from connected devices, allowing you to program their interactions for both **physical automation** and **data interchange**, all from a single, no-code interface. Built on a **drag-and-drop d** **esign environment**, MiConnect gives you complete control over how your machines, sensors, and systems work together—without the need for custom code or complex integration. And because we all know how often processes evolve, MiConnect is designed to adapt. Its intuitive interface makes it easy to modify workflows, reconfigure connections, and scale your automation strategy— **anytime your production needs change.** ## The Real Impact of Connected Automation When your machines are connected and your automation is fully integrated, you unlock the true potential of your investments. Productivity improves because information flows instantly where it’s needed. Quality increases because errors are caught and corrected before they become scrap. And your operators are freed from tedious data entry, allowing them to focus on higher-value work. This is what we mean by **automation that works for you—not the other way around.** And the best part? You don’t need to overhaul your entire shop floor or start from scratch. MiConnect works with what you already have, helping you build a smarter, more connected manufacturing environment at your own pace. ## Looking Ahead with Automation This is just one piece of the puzzle when it comes to modern manufacturing challenges. In upcoming editions of this newsletter, we’ll tackle more industry problems and offer solutions that make automation practical, achievable, and profitable. If you’re ready to explore how MiConnect can simplify your automation strategy—or you just want to talk through your shop’s specific integration challenges— [reach out to our team](https://www.caroneng.com/contact/) or visit [caroneng.com](https://www.caroneng.com/) to learn more. Let’s make automation work the way it’s supposed to— **for you**. ## Related Technology for CNC Machining ### Streamlined Process Automation Software ### Automated CNC Offset Control Software ### RFID Tool Data Management System ## Partners and Affiliations --- ## [How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems](https://www.caroneng.com/how-to-automate-legacy-manufacturing-systems) # How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems For many manufacturers, automation feels like an all-or-nothing proposition. If you’re running older CNC machines, legacy controls, or long-established manual processes, the idea of “going automated” can seem overwhelming—or worse, risky. But here’s the truth: **you don’t need to replace your machines to modernize them.** Automation doesn’t have to be disruptive, expensive, or complicated. The key is knowing how to integrate automation gradually and strategically into your existing systems—and doing it in a way that brings immediate benefits. At Caron Engineering, we work with manufacturers every day who face this exact challenge. Whether they’re running reliable but aging machines or dealing with isolated automation cells, they all ask the same thing: _How do we make this work together without starting over?_ ## The Real Challenge of Legacy Systems Legacy manufacturing systems weren't built with today's automation in mind. Machines with different controls, manual data entry, and disconnected workflows are still common. While these machines can continue producing parts, they create challenges: - **No visibility into real-time cutting conditions** - **Tools running until failure instead of to optional wear limits** - **Operators forced to run conservatively to avoid breakage** - **Higher scrap rates** - **Limited connectivity for data collection or supervisory reporting** The bigger risk is doing nothing- sticking with outdated processes while competitors embrace automation, increase throughput, and lower costs. So, how do you modernize legacy systems without turning your shop upside down? ## TMAC: Cutting Optimization and Real-Time Tool Monitoring for any CNC One of the fastest, most impactful steps is adding **[TMAC (Tool Monitoring Adaptive Control)](https://www.caroneng.com/products/tmac/)** to your legacy machines. TMAC continuously measures spindle motor power during every cut, analyzing the load profile in real time. With this information, TMAC can: - **Optimize cutting performance** by automatically adjusting feed rates to maintain efficient, stable cutting. - **Detect tool wear** by tracking changes in spindle load, allowing predictable replacement before failure. By capturing this data digitally, TMAC gives manufacturers a far more accurate picture of actual tool life – enabling tools to be used closer to their true limits instead of being swapped out prematurely. - **Catch tool breakage instantly** by recognizing abnormal load spikes and stopping the machine to prevent part or spindle damage. This combination of adaptive control and monitoring transforms even decades-old CNCs into smart machining centers. Instead of relying on conservative programs, TMAC enables machines to react to real-world conditions on the fly- extracting maximum performance while extending tool life, protecting the machine and tooling, and ensuring consistent part quality. And because TMAC integrates directly with most CNCs regardless of age or control type, it delivers automation benefits without expensive retrofits or replacements. ## MiConnect: Turning Legacy Signals into Actionable Data While TMAC enhances and protects cutting at the spindle, [**MiConnect**](https://www.caroneng.com/miconnect-technology/) **extends automation visibility and control across the shop floor-** especially for legacy equipment. MiConnect can **read I/O signals directly from older CNCs and peripheral devices**, capturing critical status information such as machine cycle state, alarm conditions, or automation handshakes. These signals can then be combined with data from TMAC or other devices into one configurable workflow. Beyond monitoring, MiConnect also has the ability to **control machine functions by writing outputs back to the machine’s I/O**. This makes it possible to add automation steps- such as triggering peripheral equipment, signaling robots, or automating manual interventions- that were never part of the machine’s original design. Finally, MiConnect pushes all of this information upward into supervisory and enterprise systems using its **REST API interface**. That means legacy machines can now feed tool monitoring events, machine status. and automation signals directly into MES, SCADA, ERP, or cloud platforms-bridging the gap between the shop floor and enterprise-level visibility. ## Real Impact, Real Fast Modernizing legacy machines isn’t about “catching up”—it’s about making what you already have work smarter. With **TMAC**, you gain real-time tool wear and breakage detection, cutting optimization accurate digital tool life monitoring. With **MiConnect**, you not only expose hidden machine signals but also gain the ability to control machine functions and integrate data into supervisory systems. And with [**AutoComp**](https://www.caroneng.com/products/autocomp/), you take the final step: automating dimensional control. AutoComp ingests measurement data from **electronic gauges, CMMs, scanning systems, vision devices, or even digital calipers**, compares the results against tolerance limits, and writes the required tool offset adjustments directly into the CNC. No manual data entry, no operator judgment—just fast, accurate corrections applied in real time. Together, TMAC, MiConnect, and AutoComp create a **fully connected and optimized manufacturing environment**—built around the machines you already own, without costly retrofits or complete system overhauls. ## Ready to Get Started? If you’re ready to bring adaptive control, data-interchange, or closed-loop feedback to your legacy machines—or want to design a phased automation strategy tailored to your shop—reach out to our team at [**caroneng.com**](https://www.caroneng.com/). ## Related Products ### Automated CNC Offset Control Software ### Adaptive Tool Monitoring System ### Streamlined Process Automation Software ## IMTS 2026 Highlights --- ## [Visit Caron Engineering at IMTS 2026 — Booth 134742](https://www.caroneng.com/imts-2026) # Visit Caron Engineering at IMTS 2026 — Booth 134742 [Add us to your IMTS show planner](https://www.caroneng.com/products/smart-light/ "Add us to your IMTS show planner") At [**IMTS 2026**](https://www.imts.com/), Caron Engineering will showcase technology designed to close the loop between cutting, measurement, and automation. From real-time tool monitoring and adaptive control to automated tool data transfer and dimensional feedback, our solutions help manufacturers run more confidently and automate production with greater reliability—driving measurable improvements across every stage of the process: _**Reduce Scrap. Shorten Cycle Time. Extend Tool Life. Improve Quality. Enable Lights-Out Machining. Eliminate Errors. Connect & Control Your Operations.**_ **Chicago, IL \| September 14-19, 2026** — Visit our booth to see how intelligent process control can transform the way your shop manages machining operations. ## Technologies to See at IMTS \| Caron Engineering Booth Caron Engineering will be demonstrating all of their automation and process control technologies designed to improve machining stability, protect high-value parts, and streamline production workflows. **_**Visitors can explore these technologies IN ACTION on a live-cutting, full-automated machining cell:**_** - Real-time CNC tool monitoring and adaptive control - Automated dimensional feedback and offset compensation - RFID-based tool data management and transfer - Low-code manufacturing automation applications - Seamless device communication and system integration for full cell orchestration - Advanced sensor analysis for machine health and performance [FANUC Robodrill CNC with Caron Engineering Solutions \| Fully-Automated High Speed VMC Demo](https://www.youtube.com/watch?v=GO5zRtRDprc) [Caron Engineering](https://www.youtube.com/channel/UCcaZeqfKFaUJF3X1QR_gsFA) [Watch on](https://www.youtube.com/watch?v=GO5zRtRDprc) _Video of our IMTS 2024 machining automation cell._ ➡ More details on live demonstrations and featured technologies coming soon. ## Caron Engineering Products Featured at IMTS 2026 - [![Tool Wear And Breakage](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Tool-Wear-and-Breakage_Caron-Engineering-circle.png)\\ \\ **TMAC - Tool Monitoring Adaptive Control**](https://www.caroneng.com/products/tmac/) - [![MiConnect Technology Flow Chart_Caron Engineering](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/MiConnect-Technology-Flow-Chart_Caron-Engineering-1-circle.png)\\ \\ **MiConnect - Low Code CNC Application Builder**](https://www.caroneng.com/miconnect-technology/) - [![Automated Tool Compensation tool and screenshot](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Automated-Tool-Compensation_Caron-Engineering-circle.png)\\ \\ **AutoComp - Automated Tool Wear Compensation**](https://www.caroneng.com/products/autocomp/) - [![ToolConnect Icon_Caron Engineering](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/ToolConnect-Icon_Caron-Engineering-circle.jpg)\\ \\ **ToolConnect - Automated CNC Tool Loading**](https://www.caroneng.com/products/toolconnect/) - [![Spindle Vibration Sensor_Caron Engineering](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/Bar-Feeder-Vibration-Header-Image-circle.png)\\ \\ **DTect-IT - CNC Sensor Analysis System**](https://www.caroneng.com/products/dtect-it/) - [![Smart Light Modes_Caron Engineering](https://www.caroneng.com/wp-content/uploads/bb-plugin/cache/SL-Segment-Mode_Caron-Engineering-circle.png)\\ \\ **CEI Smart Light - Customizable CNC Status Light System**](https://www.caroneng.com/products/smart-light/) [Contact Us to Learn More!](https://www.caroneng.com/contact/ "Contact Us to Learn More!") ## IMTS 2026 FAQs: What Manufacturers Need to Know What is IMTS 2026 and where is it held? International Manufacturing Technology Show (IMTS 2026) is one of the largest manufacturing trade shows in North America, held at McCormick Place in Chicago, Illinois. It brings together global manufacturers to explore the latest CNC machining, automation, and production technologies. What can I expect to see at Caron Engineering’s IMTS booth? Visitors can experience live demonstrations of CNC automation in action, including real-time [tool monitoring](https://www.caroneng.com/products/tmac/), adaptive control, automated tool data transfer, and connected manufacturing automation systems and workflows designed to reduce scrap and improve efficiency. Technology will be featured on a fully-automated machining cell in booth 134742. Why should I visit Caron Engineering at IMTS 2026? Caron Engineering showcases how to move beyond basic automation by integrating real-time process control. Attendees will learn how to protect high-value parts, extend tool life, and enable more reliable unattended machining. How do I register for IMTS 2026 and plan my visit? You can register for IMTS 2026 through the official [IMTS website](https://www.imts.com/) and plan your visit by reviewing exhibitor listings, booth locations, and show schedules in advance to maximize your time at the event. Create an IMTS account and add exhibitors to your show planner to maximize your time at the show. ## Where to Find Caron Engineering at IMTS 2026 Caron Engineering **Booth 134742** is located in the **Lakeside Center, EAST Building, Level 3.** 📆 September 14 - 19, 2026 📍McCormick Place \| Chicago, IL 🎟️ Register **[Here](https://www.imts.com/show/reg.cfm)**! [![IMTS Floor Plan_Caron Engineering](https://www.caroneng.com/wp-content/uploads/IMTS-Floor-Plan_Caron-Engineeirng.png)](https://directory.imts.com/8_0/floorplan/index.cfm?hallID=13&selectedBooth=134742) ## Countdown to IMTS 2026 - CHICAGO ### 124 ### Days ### 19 ### Hours ### 26 ### Minutes ### 45 ### Seconds ## Plan Your Visit to IMTS 2026! [![Plan Your Visit_IMTS](https://www.caroneng.com/wp-content/uploads/Plan-Your-Visit.png)](https://directory.imts.com/8_0/exhibitor/00045661/Caron-Engineering-Inc) #### [Plan Your Visit](https://directory.imts.com/8_0/exhibitor/00045661/Caron-Engineering-Inc) [![Registration_IMTS](https://www.caroneng.com/wp-content/uploads/Registration.png)](https://www.imts.com/show/reg.cfm) #### [Attendee Registration](https://www.imts.com/show/reg.cfm) [![Show Details_IMTS](https://www.caroneng.com/wp-content/uploads/Show-Details.png)](https://www.imts.com/show/abouttheshow.cfm) #### [IMTS Show Details](https://www.imts.com/show/abouttheshow.cfm) ## Request a Quote --- ## [Request a Quote Form](https://www.caroneng.com/request-a-quote) # Request a Quote Form Please complete the form below and our team will follow up with a quote based on your specific requirements. - \\* Required Field - Name\* FirstLast - Email\* - Phone\* - Stay Connected Via SMS Messages - [ ] I give my consent to receive SMS messages from Caron Engineering. 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Trade Show / Open houseOnline SearchSocial Media (Linkedin, YouTube, Instagram, etc.)Email/AdvertisementRepeat CustomerReferralOther - reCAPTCHA Recaptcha requires verification. I'm not a robot reCAPTCHA - Phone Notifications reCAPTCHA ## Caron Engineering News --- ## [Look for Us at These Upcoming Events!](https://www.caroneng.com/news) # Look for Us at These Upcoming Events! Montreal Manufacturing Technology Show \| May 11-12 \| Canada **DATES:** May 11-12, 2026 **TIMES:** Monday \| 9:00 AM – 7:00 PM Tuesday \| 9:00 AM – 6:00 PM **LOCATION:** Mo1001 Place Jean-Paul-Riopelle \| Montréal, QC H2X 1H5 [REGISTER HERE!](https://www.mmts.ca/) Concept Machine Tool SteakFest Open House \| May 12-13 \| Delafield, WI **DATES:** May 12-13, 2026 **TIMES:** 10:00AM - 7:00PM **LOCATION:** 407 Austin Circle \| Delafield, WI 53018 [REGISTER HERE!](https://www.conceptmachine.com/event/steakfest-2026-open-house/) Morris Charlotte Open House \| May 12-13 \| Charlotte, NC **DATES:** May 12-13, 2026 **TIMES:** 9:00AM - 4:00PM **LOCATION:** 8530 Steele Creek Place Drive, Suite H \| Charlotte, NC 28273 [REGISTER HERE!](https://events.gotomorris.com/engineered-to-outperform-summit) Lang Technik Grand Opening \| May 12 \| Hartland, WI **DATES:** May 12, 2026 **TIMES:** 9:00AM - 5:00PM **LOCATION:** 1025 Walnut Ridge Drive \| Hartland, WI 53029 [REGISTER HERE!](https://lang-technik-usa.com/en/grand-opening) REGO FIX Indy Days \| May 13-14 \| Whitestone, IN **DATES:** May 13-14, 2026 **TIMES:** 9:00AM - 9:00PM **LOCATION:** 4420 Anson Blvd. \| Whitestown, IN 46075 [REGISTER HERE!](https://regousa.com/event/indydays/) Wolfram Manufacturing Technologies Open House \| May 15 \| Austin, TX **DATE:** May 15, 2026 **TIMES:** 9:00AM - 3:00PM **LOCATION:** 8505 Cross Park Dr \| Austin, TX 78754 Morris WI Advanced Manufacturing \| June 4 \| Waukesha, WI **DATES:** June 4, 2026 **TIMES:** 10:00 am - 6:00 pm **LOCATION:** 2323 Corporate Drive \| Waukesha, WI 53189 [REGISTER HERE!](https://events.gotomorris.com/morris-advanced-manufacturing-day-2026-registration?hsCtaTracking=f39d04a8-1f4d-49c6-90c8-d6ddf643c122%7C37dcc4e4-7d71-4f27-9faf-eb8e55d26b24) Nidec & Wenzel Open House \| June 9-10 \| Wixom, MI **DATES:** June 9-10, 2026 **LOCATION:** 46992 Liberty Dr \| Wixom, MI 48393 (Nidec Machine Tool America) **LOCATION:** 28700 Beck Rd \| Wixom, MI 48393 (Wenzel America) [REGISTER HERE!](https://www.wenzelamerica.com/event/gear-up-for-precision-open-house/) Opti Pro Machine Tool Open House \| June 10-11 \| Ontario, NY **DATES:** June 10-11th, 2026 **TIME:** 10:00AM - 4:00PM **LOCATION:** 6368 Dean Parkway \| Ontario, NY 14519 [REGISTER HERE!](https://www.optipro.com/technology-open-house/) Gosiger Indiana Open House \| June 17 \| Indianapolis, IN **DATES:** June 17, 2026 **TIMES:** 10:00AM - 2:00PM **LOCATION:** 4627 Independence Sq \| Indianapolis, IN 46203 IMTS 2026 \| September 14-19 \| Chicago, IL **DATES:** September 14-19, 2026 **TIMES:** 10:00AM - 6:00PM **LOCATION:** McCormick Place \| Chicago, IL 60616 [REGISTER HERE!](https://www.imts.com/show/reg.cfm) [![Image IMTS2026_Caron Engineering](https://www.caroneng.com/wp-content/uploads/ADD-US-TO-YOUR-SHOW-PLANNER-2.png)](https://directory.imts.com/8_0/login/login.cfm) # Caron Engineering News [![](https://www.caroneng.com/wp-content/uploads/Real-Time-Adaptive-Control-Header-Image-300x169.png)](https://www.caroneng.com/real-time-adaptive-control-the-key-to-faster-more-stable-machining/ "Real-Time Adaptive Control: The Key to Faster, More Stable Machining") ## [Real-Time Adaptive Control: The Key to Faster, More Stable Machining](https://www.caroneng.com/real-time-adaptive-control-the-key-to-faster-more-stable-machining/ "Real-Time Adaptive Control: The Key to Faster, More Stable Machining") Adaptive control brings real-time visibility to your cutting process—helping prevent failures, extend tool life, and protect part quality in demanding materials. [Read More about Real-Time Adaptive Control: The Key to Faster, More Stable Machining](https://www.caroneng.com/real-time-adaptive-control-the-key-to-faster-more-stable-machining/ "Real-Time Adaptive Control: The Key to Faster, More Stable Machining") [![](https://www.caroneng.com/wp-content/uploads/Modernizing-Legacy-Systems-Header-300x169.png)](https://www.caroneng.com/how-to-automate-legacy-manufacturing-systems/ "How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems") ## [How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems](https://www.caroneng.com/how-to-automate-legacy-manufacturing-systems/ "How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems") Many manufacturers assume automation requires replacing legacy machines or rebuilding the entire shop floor. In reality, most modernization efforts succeed by connecting and enhancing the \[…\] [Read More about How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems](https://www.caroneng.com/how-to-automate-legacy-manufacturing-systems/ "How to Seamlessly Transition to Automated Processes in Legacy Manufacturing Systems") [![](https://www.caroneng.com/wp-content/uploads/Next-Gen-Software_Caron-Engineering-300x163.png)](https://www.caroneng.com/wp-content/uploads/Next-generation-application-builder_-caron_engineering.pdf "A Next Generation Application Builder for Manufacturing Process Automation and Interconnectivity") ## [A Next Generation Application Builder for Manufacturing Process Automation and Interconnectivity](https://www.caroneng.com/wp-content/uploads/Next-generation-application-builder_-caron_engineering.pdf "A Next Generation Application Builder for Manufacturing Process Automation and Interconnectivity") For fabricators who have ever wished to self-build applications to suit their unique manufacturing processes, the dream has, at long last, materialized, thanks to Caron \[…\] [Read More about A Next Generation Application Builder for Manufacturing Process Automation and Interconnectivity](https://www.caroneng.com/wp-content/uploads/Next-generation-application-builder_-caron_engineering.pdf "A Next Generation Application Builder for Manufacturing Process Automation and Interconnectivity") [![](https://www.caroneng.com/wp-content/uploads/Precision-in-Process-LinkedIn-300x169.png)](https://www.caroneng.com/precision-in-process-closing-the-loop-with-electronic-gauging-and-automated-tool-offsets/ "Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets") ## [Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets](https://www.caroneng.com/precision-in-process-closing-the-loop-with-electronic-gauging-and-automated-tool-offsets/ "Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets") Tool wear and dimensional drift are unavoidable in precision machining. Most shops already measure parts with electronic gauges, probes, or CMMs. The real opportunity appears \[…\] [Read More about Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets](https://www.caroneng.com/precision-in-process-closing-the-loop-with-electronic-gauging-and-automated-tool-offsets/ "Precision in Process: Closing the Loop with Electronic Gauging and Automated Tool Offsets") [![](https://www.caroneng.com/wp-content/uploads/Image-3_Bar-Feeder-Vibration-Sensor_Caron-Engineering-300x169.png)](https://www.advancedmanufacturing.org/technologies/software-update/why-ai-powered-monitoring-is-the-next-step-for-cnc-machining/article_ec70ca82-3e89-48c6-93d5-7d920ef04e91.html?utm_source=delivra&utm_medium=email&utm_campaign=MW-1.9.2026-ACTUAL&utm_id=10086786&dlv-emuid=fcf8e205-438f-4fa2-837b-6f78c1023d02&dlv-mlid=10086786 "Why AI-Powered Monitoring is the Next Step for CNC Machining") ## [Why AI-Powered Monitoring is the Next Step for CNC Machining](https://www.advancedmanufacturing.org/technologies/software-update/why-ai-powered-monitoring-is-the-next-step-for-cnc-machining/article_ec70ca82-3e89-48c6-93d5-7d920ef04e91.html?utm_source=delivra&utm_medium=email&utm_campaign=MW-1.9.2026-ACTUAL&utm_id=10086786&dlv-emuid=fcf8e205-438f-4fa2-837b-6f78c1023d02&dlv-mlid=10086786 "Why AI-Powered Monitoring is the Next Step for CNC Machining") Forget the Andon lights. Skip the paper job cards. Integrated, real-time machine monitoring is the clear path forward for any shop pursuing a digital transformation. \[…\] [Read More about Why AI-Powered Monitoring is the Next Step for CNC Machining](https://www.advancedmanufacturing.org/technologies/software-update/why-ai-powered-monitoring-is-the-next-step-for-cnc-machining/article_ec70ca82-3e89-48c6-93d5-7d920ef04e91.html?utm_source=delivra&utm_medium=email&utm_campaign=MW-1.9.2026-ACTUAL&utm_id=10086786&dlv-emuid=fcf8e205-438f-4fa2-837b-6f78c1023d02&dlv-mlid=10086786 "Why AI-Powered Monitoring is the Next Step for CNC Machining") [![](https://www.caroneng.com/wp-content/uploads/Missing-Link-in-Automation-Featured-Image-1-300x169.png)](https://www.caroneng.com/the-missing-link-in-automation-how-to-get-your-machines-talking-without-the-headaches/ "The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)") ## [The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)](https://www.caroneng.com/the-missing-link-in-automation-how-to-get-your-machines-talking-without-the-headaches/ "The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)") Automation should make production easier. For many shops, the real challenge begins when machines, robots, gauges, and software all need to communicate. Integration turns into \[…\] [Read More about The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)](https://www.caroneng.com/the-missing-link-in-automation-how-to-get-your-machines-talking-without-the-headaches/ "The Missing Link in Automation: How to Get Your Machines Talking (Without the Headaches)") [![](https://www.caroneng.com/wp-content/uploads/Tool-Life-Tracking_Caron-Engineering-300x218.png)](https://www.caroneng.com/news/new-advanced-cnc-tool-tracking-toolconnect/ "New Advanced CNC Tool Tracking with ToolConnect RFID") ## [New Advanced CNC Tool Tracking with ToolConnect RFID](https://www.caroneng.com/news/new-advanced-cnc-tool-tracking-toolconnect/ "New Advanced CNC Tool Tracking with ToolConnect RFID") Caron Engineering’s ToolConnect system—an intelligent tool management solution that automates the transfer of presetter-measured tool data to CNC controls via RFID tags in tool holders—now offers \[…\] [Read More about New Advanced CNC Tool Tracking with ToolConnect RFID](https://www.caroneng.com/news/new-advanced-cnc-tool-tracking-toolconnect/ "New Advanced CNC Tool Tracking with ToolConnect RFID") [![](https://www.caroneng.com/wp-content/uploads/Ulli-Correct-Size-1-300x190.png)](https://www.caroneng.com/news/caron-engineering-welcomes-ulli-thornton-as-western-us-regional-sales-manager/ "Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager") ## [Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager](https://www.caroneng.com/news/caron-engineering-welcomes-ulli-thornton-as-western-us-regional-sales-manager/ "Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager") Caron Engineering, a leading provider of tool monitoring, automation, and process control technology for manufacturing, is pleased to announce the addition of Ulli Thornton as \[…\] [Read More about Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager](https://www.caroneng.com/news/caron-engineering-welcomes-ulli-thornton-as-western-us-regional-sales-manager/ "Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager") [![](https://www.caroneng.com/wp-content/uploads/Digital-Factory-with-MiConnect-Thumbnail_Caron-Engineering-300x180.png)](https://www.caroneng.com/news/woodward-digital-factory/ "Setting Up the Building Blocks for a Digital Factory") ## [Setting Up the Building Blocks for a Digital Factory](https://www.caroneng.com/news/woodward-digital-factory/ "Setting Up the Building Blocks for a Digital Factory") Running a digital factory is a tricky task, however you define “digital factory.” At Woodward Inc., a manufacturing company that tackles energy control in both aerospace \[…\] [Read More about Setting Up the Building Blocks for a Digital Factory](https://www.caroneng.com/news/woodward-digital-factory/ "Setting Up the Building Blocks for a Digital Factory") - 1 - [2](https://www.caroneng.com/news/page/2/) - [3](https://www.caroneng.com/news/page/3/) - … - [5](https://www.caroneng.com/news/page/5/) - [Next »](https://www.caroneng.com/news/page/2/) Load More News ## Micro Component Productivity --- ## [A Productivity Boost for Micro Sized Components](https://www.caroneng.com/news/a-productivity-boost-for-micro-sized-components) # A Productivity Boost for Micro Sized Components [Read the full article here](https://www.mfgnewsweb.com/archives/4/55856/Applying-Technology-dec19/A-Productivity-Boost-for-Micro-Sized-Components.aspx) ## CEI Smart Light System --- ## [Advanced Solution for Machine Status Reporting with the CEI Smart Light System](https://www.caroneng.com/news/advanced-solution-for-machine-status-reporting-with-the-cei-smart-light-system) # Advanced Solution for Machine Status Reporting with the CEI Smart Light System “A typical status light essentially has three color indicators that tell you whether the (1) machine is running, (2) in feed hold or (3) alarm,” said a company spokesperson. “In a typical machine shop, an operator will continually check each machine in a cell to view the status of the part program to determine when it will need attention. This requires manual labor and typically results in excessive machine downtown, as machines unavoidably sit idle waiting for an operator to check the status. Read the full article [here](https://www.mfgnewsweb.com/archives/1/49077/Plant-Maintenance-jun17/Advanced-Solution-for-Machine-Status-Reporting.aspx) ## Caron Joins OMIC R&D --- ## [Caron Engineering Joins OMIC R&D as 26th Member](https://www.caroneng.com/news/caron-engineering-joins-omic-rd-as-26th-member) # Caron Engineering Joins OMIC R&D as 26th Member * * * Read the full article [here](https://www.omic.us/announcements/post/caron-engineering-leader-in-optimization-technology-for-metals-manufacturing-joins-omic-rd-as-26th-member) ## Performance Intelligence Partnership --- ## [Datanomix and Caron Engineering Partner to Deliver Real-time Performance Intelligence for Precision Manufacturers](https://www.caroneng.com/news/datanomix-and-caron-engineering-partner-to-deliver-real-time-performance-intelligence-for-precision-manufacturers) # Datanomix and Caron Engineering Partner to Deliver Real-time Performance Intelligence for Precision Manufacturers _![](https://www.caroneng.com/wp-content/uploads/Datanomix-Dash-300x205.png)Joint development will start with visualizing Caron Engineering_ _TMAC tool performance data in a comprehensive Datanomix dashboard_ EASTEC 2021 – October 19, 2021 – Datanomix, the leading automated production intelligence platform, and Caron Engineering, the leader in manufacturing tool optimization technologies, today announced a partnership to jointly develop data-driven solutions that leverage the companies’ manufacturing domain expertise in real-time production monitoring and machine tool optimization. This integration adds a new dashboard in the Datanomix platform that aggregates and displays the metrics for all Caron devices deployed in a factory. At Eastec they will show a single visualization for the job performance data from Caron Engineering’s adaptive tool monitoring system, TMAC, helping accelerate continuous improvement efforts across all jobs. The data generated by today’s manufacturing machines offers tremendous opportunities to drive production insights, and Datanomix is using advanced analytics and machine learning to empower manufacturers to understand the state of their production in real time. Caron Engineering uses advanced sensors and signal processing techniques to improve machine performance, optimizing how CNC machines produce parts and measure tool usage to track tool wear and prevent costly repairs. This partnership and its resulting technology will help manufacturers proactively optimize whole-factory performance and profitability. “Manufacturers are demanding an integrated solution that delivers a rich visual experience around real-time job performance, predictive machine parameters, and cutting tool behavior over time,” said John Joseph, CEO and co-founder of Datanomix. “The combination of Caron Engineering and Datanomix delivers more real-time data for production than any other solution, providing incredible opportunities to apply data science to an industry segment in need of contextualized production intelligence. Together we will build the next generation of analytics solutions for precision manufacturers that covers the entire machine and production workflow.” “There is a symbiotic fit between the tooling expertise at Caron and the data science capabilities at Datanomix,” said Rob Caron, founder and president of Caron Engineering. “This partnership lets us offer our installed base of thousands of customers worldwide an analytics and intelligence solution that spans from the cutting tools and machine health all the way to the executive suite. Data is at the heart of Caron’s strategy, and with Datanomix, we will be able to leverage our combined data into actionable insights that will help transform manufacturing at a practical level.” Development efforts have been focused on integrating data from Caron systems for analysis and visualization through the Datanomix platform in the following ways: - **TMAC (Tool Monitoring Adaptive Control):** A new Datanomix dashboard will display the status of every TMAC-enabled machine in the factory for a consolidated view of performance that accelerates job-level continuous improvement. Datanomix will present Caron performance parameters, including horsepower, vibration, pressure, strain, and coolant information for each TMAC machine. Users will be able to create alerts for out-of-tolerance conditions for rapid responses. Other Datanomix production charts and graphs for associated machines will include an active Caron Engineering icon that will let users drill down to Caron tool performance for that machine. - **DTect-IT (Machine Condition Monitoring):** DTect-IT combines high-precision sensor technology with advanced analysis to monitor, detect, and correct anomalies in the machining process. Datanomix enables customers who need deeper analytics and optimization strategies for cutting unique parts to visualize DTect-IT data in the Datanomix platform. Existing Datanomix customers will be able to schedule installation of DTect-IT on any machine by clicking a purchase button in the Datanomix platform. - **AutoComp (Automatic Tool Wear Compensation Software):** AutoComp processes measurement data from any electronic gauging device and automatically calculates and compensates tool offsets in the control, without any operator intervention. Datanomix can compare this part quality data with cutting data from the above systems. - **ToolConnect: (Tool Data Management System):** ToolConnect automates the process of loading tools into the machine by automatically transferring tool offset data directly from the presetter to the CNC control, via RFID tags embedded in tool holders and 2D presetter-printed barcodes. The system is completely customizable to meet the users’ tool load specifications and records every step, action, and data exchange. This data is valuable as Datanomix analyzes how variations in tool geometry affect cutting data. “With Caron’s focus on data, it was a natural fit to collaborate on advanced analytics and visualizations.” said Greg McHale, CTO and co-founder of Datanomix. “Customers who implement Caron or Datanomix are looking to understand exactly what’s happening with every part they manufacture. We envision a data-driven future that visualizes production starting with raw materials, to machining, to the finished part, leaving manufacturers with insights into productivity, continuous improvement, maintenance, and business optimization. We couldn’t ask for a better partner than Rob Caron and his team to accelerate this future for our customers and theirs.” Both Caron and Datanomix put customers first, and feedback and suggestions from customers have been a critical aspect of designing and developing solutions that deliver added value for users of both companies’ solutions. “At Nikel Precision Group, data and analytics are core value drivers, helping us meet our customers’ exacting requirements and demanding production schedules,” said James Bell, vice president of operations at Nikel Precision Group LLC. “As a customer of both Caron and Datanomix, Nikel Precision Group is getting tremendous value from the real-time data driven by each of their solutions. We’re excited about the potential enabled by the depth of experience in manufacturing and data science of these two teams.” Existing customers for both companies will have the opportunity to purchase these software tools through existing sales channels. The companies have worked out a reciprocal support network to route customer requests to the technical experts at each company providing the highest level of quality in their support experience. This partnership has created career openings at both companies across engineering, customer support, and sales. Datanomix and Caron Engineering are exhibiting at the 2021 Eastec Conference in West Springfield, Massachusetts from October 19–21. Product demonstrations will be available in booth 5519 with Datanomix and booth 5432 with Caron Engineering. **_About Datanomix_** _Based in New Hampshire, Datanomix provides real-time production monitoring and performance analytics for CNC machines, without the need for operator inputs or links to ERP systems. Datanomix’s mission is to level the data analytics playing field for industrial manufacturers by giving them robust decision-making tools so they can proudly build world-class products. Learn more at_ [_www.datanomix.io_](http://www.datanomix.io/) _._ **_About Caron Engineering_** _Founded in 1986, Caron Engineering develops advanced sensor and monitoring technology for CNC machines that interface directly with almost any control on the market to optimize and automate manufacturing processes. Their smart factory solutions focus on unattended operation, machine health and process diagnostics, tool wear and breakage detection, automatic tool offsetting, cycle time reduction, and eliminating operator error._ ## Manufacturer's Tech Success --- ## [Michigan Manufacturer Wins Big with Early Adoption of Cutting-edge Technology](https://www.caroneng.com/news/michigan-manufacturer-wins-big-with-early-adoption-of-cutting-edge-technology) # Michigan Manufacturer Wins Big with Early Adoption of Cutting-edge Technology Read the full article [here](https://www.sme.org/technologies/articles/2021/january/first-times-the-charm/) ## Smart Manufacturing Comeback --- ## [Smart Manufacturing Systems: The Covid-19 Comeback](https://www.caroneng.com/news/smart-manufacturing-systems-the-covid-19-comeback) # Smart Manufacturing Systems: The Covid-19 Comeback Reduced availability of skilled workers has been a modern development even before the pandemic. Now, with shops closing down or limiting operations and number of workers permitted on the shop floor, the need to have operations functioning without operator presence, and add value to your current equipment to optimize manufacturing processes, is the direction of the present and future of manufacturing. **Automate and Optimize Setup Procedures.** Integrating automation in the tool load process, combined with offline tool measurement greatly reduces setup time, eliminates common data entry errors, and prohibits operators from inadvertently loading the wrong tools into the machine. Caron Engineering has developed a sophisticated retrofit tool identification system that is customized to fit the customer’s tool load process and requirements. ToolConnect uses RFID tags embedded in tool holders to automatically transfer tool presetter data to the machine control via their custom control interface. This system reads and writes all tool measurement and tool life information to and from the tag, which is read and processed by a custom read station. The intuitive user interface provides a visual of all tool measurement data, picture, and process flow for the operator. ToolConnect even has the failsafe option of indexing to the correct magazine position to eliminate any margin for error. **Run Unattended.** Real-time tool monitoring can optimize the machine tool cutting process to increase shop productivity. By monitoring tool wear in real-time, a system like TMAC (Caron Engineering’s Tool Monitoring Adaptive Control system) can react instantaneously to wear and extreme conditions, and stop and expire tools, without the need for operator intervention. This system offers advanced adaptive control capabilities, allowing TMAC to take over the machine tool feedrate to automatically reduce the feedrate with high power cuts and increase the feedrate with low power cuts, to maximize tool life and reduce cycle time (up to 60%). Customers machining hard and difficult to machine materials will realize significant benefits with adaptive control. This system allows manufacturers to run unattended operations, with confidence. By extending tool life, reducing cycle time, and preventing damage from extreme conditions, this system provides an almost immediate return on investment. **Closing the Loop.** Eliminating the manual calculation of tool and wear offsets after part measurement saves time and eliminates the potential for data-entry errors that can result in excessive scrap or possible machine damage. Caron Engineering’s AutoComp software processes the measurement file from almost any electronic gauging device and automatically calculates and compensates offsets in the CNC control. This happens without any operator intervention. This software also calculates tool life and has many features for customized macro-enabled alerts and data trending. “In today’s economic climate, adding value to your current equipment for more intelligent and automated manufacturing is both essential and cost-effective. Our unique technology interfaces with almost any CNC control on the market, making us a single source solution to optimize productivity on your shop floor”, said Rob Caron, President of Caron Engineering. To learn more about Caron Engineering’s smart manufacturing technology, visit [www.caroneng.com](http://www.caroneng.com/). _Caron Engineering, Inc._ _116 Willie Hill Rd._ _Wells, ME 04090_ +1- _207-646-6071_ [marketing@caroneng.com](mailto:marketing@caroneng.com) [www.caroneng.com](http://www.caroneng.com/) ## Engineering Video Game Innovation --- ## [Using Tech to Make Engineering the Best Video Game there is](https://www.caroneng.com/news/using-tech-to-make-engineering-the-best-video-game-there-is) # Using Tech to Make Engineering the Best Video Game there is The lone star state is filled with idioms, traditions, and a uniqueness that can best be described as …..Texas. Depending on where you’re from “everything is bigger, no one should mess with you and something about playing with bulls and getting the horns are considered to be universal truths. Never eat chili with beans, and don’t be the person who is all hat and no cattle. But one saying you don’t hear a lot of is “I’m opening a machine shop and not hiring machinists.” Read the full article [Here](http://www.cnc-west.com/wolfram-manufacturing-using-tech-to-make-manufacturing-the-best-video-game-there-is/) ## New Production Technology Center --- ## [Wolfram Manufacturing: New Production Technology Center in Texas](https://www.caroneng.com/news/caron-engineering-and-wolfram-manufacturing-to-open-new-production-technology-center-in-texas) # Wolfram Manufacturing: New Production Technology Center in Texas Wolfram Manufacturing, a systems integrator for Caron Engineering products since 2015, has focused its business model on using the best technology manufacturing has to offer and creating an environment that appeals to the next generation of the manufacturing workforce. Wolfram is a production machine shop that has integrated Caron Engineering technology to automate and optimize productivity on all their manufacturing cells. The focus of this production technology center is to provide a centralized hub for customers to access the latest technologies for automation, cycle time reduction, unmanned operation, and total process monitoring and control for tool loading, offset adjustment, and more. Most notably the customer will see how the implementation of digital technologies has resulted in 24/7 production with little to no machine operator intervention or attendance. Some of the technology center highlights include: - A full production environment with thousands of hours of cutting time across CNCs, including mill-turns, lathes, mills, EDMs, broaches, and Swiss machines. - Caron Engineering products enabling fully automated production machining. - Integration of Caron products with other technologies enhancing production management. - Training programs for the Caron product line of smart manufacturing technology. - Actionable use cases to improve ROI in any production environment. Caron Engineering and Wolfram Manufacturing hosted the official grand opening event in the spring of 2022. ## Caron Engineering and Serview Partnership --- ## [Caron Engineering Expands Systems Integrator Network in the U.S.](https://www.caroneng.com/news/new-systems-integrator-serview) # Caron Engineering Expands Systems Integrator Network in the U.S. Caron Engineering recently partnered with New Jersey-based company, Serview, to provide full service, sales, and support of their smart manufacturing technology product line. Serview will be covering systems integration in the U.S. states of New Jersey and Eastern Pennsylvania. ![](https://www.caroneng.com/wp-content/uploads/Serview-Post-Image_Caron-Engineering-300x200.jpg) Serview is a family-owned integration services company with CAD/CAM/CNC capabilities. They maintain an engineering focused machine shop to support both prototype and production CNC machining. They have been supplying advanced machine vision technology and systems integration services for the manufacturing industry for over 23 years. Owners and brothers, Steve and Brian LeBlanc, bring a wealth of expertise to the industry. They specialize in providing service to clients using advanced industrial automation systems and technology. Their products are in use by clients worldwide, most often in production of mass-produced items where quality is critical. Their integration experience covers a wide range of industrial technologies including PLC (programmable logic controllers) and CNC (computer numerical control) based controls systems. In addition to this, they also integrate 2D and 3D machine vision for inline process inspection. “As an integration and manufacturing company currently utilizing Caron Engineering products to optimize and automate their own production, combined with their technical knowledge and industry experience, Serview is a welcomed addition to the Caron Engineering network of systems integration specialists,” said Derek Waterman, Integrator Manager for Caron Engineering. Learn more about [Serview](https://www.serview.net/). ## EASTEC 2023 Technologies --- ## [Caron Engineering Will Feature the Latest Technologies for Automation and Process Control at EASTEC 2023](https://www.caroneng.com/news/caron-engineering-eastec-2023) # Caron Engineering Will Feature the Latest Technologies for Automation and Process Control at EASTEC 2023 Caron Engineering will be featuring their newest monitoring, automation, and process control technologies for manufacturing outfitted on a Tsugami SS327-5AX for a fully automated machining demonstration in booth 5359 at EASTEC 2023. The product highlight will be their latest software innovation, MiConnect Technology. [MiConnect Technology](https://www.caroneng.com/miconnect-technology/) is a flexible and customizable application builder specifically designed for the CNC manufacturing environment. MiConnect makes it possible for their network of integration specialists to efficiently develop unique manufacturing applications for their customers without the need for custom coding. From a simple operation of parsing a single piece of meaningful data to handling all inter-device communication across a fully automated cell, MiConnect can easily be configured for your desired process and flow. The graphical programming of the software makes it easy to tailor applications and adapt to changing requirements. And, with the continually growing inventory of pre-built drivers (CNC’s, robots, barcode scanners, I/O, Modbus, files, SQL, REST API, etc.) and numerous building blocks of operations, it allows our integration specialists to seamlessly customize any application for the customer.![](https://www.caroneng.com/wp-content/uploads/EASTEC-Product-Preview_Caron-Engineering-2.png) For their EASTEC automation demo, MiConnect will be controlling the interaction between the Tsugami CNC, a Universal Robot provided by Machine Tending Solutions, a MiJet parts cleaner, and a Fowler Precision portable CMM. An Elatec RFID badge reader will also be integrated using MiConnect Technology, for system access and user verification. Additionally, you can expect to see full demonstrations of their entire product line to include: - [**ToolConnect**](https://www.caroneng.com/products/tool-connect-rfid-tool-identification) **:** A customizable tool data management system that reads and processes presetter written RFID tags and 2D printed barcode tags to automatically update tool information directly to the CNC control. ToolConnect automates the process of loading tools into the machine to reduce setup time, eliminate human error, and prevent a wrong tool from being loaded. - [**TMAC 3.0**](https://www.caroneng.com/products/tmac-tool-monitoring-adaptive-control) **:** An adaptive tool monitoring system that measures tool wear and detects breakage in real time, with adaptive feed rate control to optimize cutting and reduce cycle time up to 60%. TMAC protects the entire machining process and has multiple integrated sensor options that can be monitored simultaneously. - [**AutoComp**](https://www.caroneng.com/products/autocomp) **:** Automated tool wear compensation software that processes almost any electronic gauge data and calculates and compensates tool offsets in the CNC control automatically; providing fast, error-free tool offset control. - [**DTect-IT**](https://www.caroneng.com/products/machine-condition-monitoring-system) **:** A CNC sensor analysis system used to detect and correct anomalies occurring in the normal machining process. Prominent applications include vibration analysis, bar feeder vibration detection, bearing analysis, signature analysis, and surface roughness analysis. - [**CEI**](https://www.caroneng.com/products/smart-light) [**Smart Light**](https://www.caroneng.com/products/smart-light) **:** Intuitive status light system with over 1000 available modes and programmable audible alarm; to indicate any machine status or condition. - [**Blum-Novotest Products**](https://www.caroneng.com/products/blum-novotest/) **:** In-process laser measurement and machine tool probing solutions. Caron Engineering has a long history of integrating technology across all CNC machine and control types. Visit them in booth 5359 to see how they can apply their automation and optimization technology to your operations. [➡️ REGISTER FOR FREE](https://www.xpressreg.net/register/east0523/landing.asp?sc=10016560E&aban=&hkey=&iq=&vip=&tm=&_ga=) ➡️ Add us to your [EASTEC SHOW PLANNER!](https://s36.a2zinc.net/clients/SME/EASTEC2023/Public/eBooth.aspx?IndexInList=0&FromPage=Exhibitors.aspx&ParentBoothID=&ListByBooth=true&BoothID=391967) [ℹ️ EASTEC](https://www.easteconline.com/?ID=6007&_ga=2.233431322.54850257.1675957364-209491083.1673368181) 2023 will be held on May 16-18 at the Eastern States Exposition in West Springfield, MA. ## Rob Caron Honored --- ## [Caron Engineering Founder, Rob Caron, Honored with Manufacturing Medal](https://www.caroneng.com/news/caron-engineering-founder-rob-caron-honored-with-manufacturing-medal) # Caron Engineering Founder, Rob Caron, Honored with Manufacturing Medal [Caron Engineering, Inc.](https://www.caroneng.com/) is proud to announce that its Founder and President, Rob Caron, has been awarded The M. Eugene Merchant Manufacturing Medal. Established in 1986 by the American Society of Mechanical Engineers (ASME) and the Society of Manufacturing Engineers (SME), this prestigious award honors exceptional individuals who have significantly improved the productivity and efficiency of manufacturing operations. Under Rob’s leadership, Caron Engineering has developed a cutting-edge product line of smart manufacturing technology. These solutions, initially ahead of their time, have become essential for modern manufacturing, interfacing seamlessly with nearly any CNC machine control on the market. Rob Caron’s visionary approach and dedication to advancing manufacturing technology have earned him this well-deserved recognition. His contributions to the industry have not only optimized productivity but also set new standards for automation, efficiency and innovation in manufacturing. The award was presented by the ASME/SME Foundation at a Luncheon on Monday, June 3rd in Long Beach, CA. ## Leadership Team Overview --- ## [New Leadership Appointments Strengthen Caron Engineering’s Vision](https://www.caroneng.com/news/leadership-team) # New Leadership Appointments Strengthen Caron Engineering’s Vision [Caron Engineering](https://www.caroneng.com/), a pioneer in tool monitoring, automation solutions, and process control technology for the CNC manufacturing industry, is proud to announce the appointment of a new C-suite leadership team to further enhance its operational excellence and technological innovation. The company, founded in 1986, continues to lead the industry with groundbreaking solutions aimed at improving manufacturing efficiency worldwide. **Rob Caron**, Founder and CEO of Caron Engineering, is pleased to introduce the following key executive appointments: **![Joel Tessier Headshot_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Joel-Tessier-Headshot.jpg)Joel Tessier, Chief Operating Officer (COO)** – With over 35 years of dedicated service, Joel Tessier has been a cornerstone of Caron Engineering’s successful operations. His depth of knowledge and commitment to excellence make him the perfect fit for the role of COO, where he will continue to oversee and optimize the company’s day-to-day functions. **![Derrill Vezina Headshot_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Derrill-Vezina-Headshot.jpg)Derrill Vezina, Chief Technology Officer (CTO)** – For over a decade, Derrill Vezina has been at the helm of the engineering department, driving technological advancements and ensuring Caron Engineering’s products remain on the cutting edge of innovation. As CTO, he will continue to lead the development of the company’s technology strategy and product portfolio. **![Brianna Toulouse Headshot_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Brianna-Toulouse-Headshot.jpg)Brianna Toulouse, Chief Marketing Officer (CMO)** – Having led the marketing department for more than 10 years, Brianna Toulouse has successfully positioned Caron Engineering as an industry leader. As CMO, she will continue to steer the company’s marketing strategy, with a focus on driving brand growth and expanding global market reach. **![Joe Gagnon Headshot_Caron Engineering](https://www.caroneng.com/wp-content/uploads/Joe-Gagnon-Headshot.jpg)Joe Gagnon, Chief Financial Officer (CFO)** – With over six years of experience managing Caron Engineering’s finance team and a background in commercial analysis and business development, Joe Gagnon brings extensive financial expertise and strategic insight to the C-suite. His leadership has been instrumental in guiding the company’s financial strategies, growth, and long-term sustainability. “With this talented team in place, I’m confident that Caron Engineering will continue to thrive and set new benchmarks for innovation and customer satisfaction in the CNC manufacturing industry,” said Rob Caron, CEO and Founder. The newly appointed C-suite will focus on driving growth, fostering innovation, and strengthening Caron Engineering’s position as a global leader in advanced manufacturing solutions. For more information about Caron Engineering, visit [www.caroneng.com](http://www.caroneng.com/). ## New National Sales Manager --- ## [Caron Engineering Promotes New National Sales Manager](https://www.caroneng.com/news/caron-engineering-promotes-new-national-sales-manager) # Caron Engineering Promotes New National Sales Manager Caron Engineering, a global leader in tool monitoring, automation solutions, and process control technology for CNC manufacturing, is proud to announce the promotion of Mike Laurendeau to National Sales Manager. “Mike has been an invaluable member of our team, consistently demonstrating a deep understanding of our customers’ needs and the manufacturing landscape,” said Rob Caron, Founder and CEO of Caron Engineering. “We are confident that in his new role as National Sales Manager, Mike will continue to drive our success, leading our sales strategy to new heights across the country.” As National Sales Manager, Mike will lead Caron Engineering’s nationwide sales efforts, collaborating with the sales team and certified product integrators to broaden the company’s market reach. For more information, visit [www.caroneng.com](https://nam11.safelinks.protection.outlook.com/?url=http%3A%2F%2Fwww.caroneng.com%2F&data=05%7C02%7Cbtoulouse%40caroneng.com%7Cff498d9ea6da43c1067408dcf51f0b72%7Cb7e3af9b11a84870a3b1425ce375af3f%7C0%7C0%7C638654760905202677%7CUnknown%7CTWFpbGZsb3d8eyJWIjoiMC4wLjAwMDAiLCJQIjoiV2luMzIiLCJBTiI6Ik1haWwiLCJXVCI6Mn0%3D%7C0%7C%7C%7C&sdata=wy%2BkZfV%2BmqVSHP8%2FeC5UqU%2BzVHAUlsKj8F5OliTvgZ8%3D&reserved=0). ## CNC Machine Tool Monitoring --- ## [Signature Analysis Tool Monitoring on CNC Machines](https://www.caroneng.com/news/new-signature-analysis-for-cnc-machine-tool-monitoring-ideal-for-constant-surface-speed-cutting-operations) # Signature Analysis Tool Monitoring on CNC Machines Caron Engineering introduces an advanced signature analysis feature for CNC machining, designed to precisely monitor the cutting forces experienced by tooling throughout the cutting path. This innovative tool monitoring capability has been integrated into our [TMAC](https://www.caroneng.com/products/tmac/) (adaptive tool monitoring system) and [DTect-IT](https://www.caroneng.com/products/dtect-it/) (CNC sensor analysis system) products. Signature analysis is critical for enhancing the reliability and efficiency of various CNC cutting processes. For example, constant surface speed cutting operations have traditionally been difficult to monitor due to fluctuating spindle RPMs as material is removed. Traditional methods often lead to unreliable results, making this supplemental tool monitoring technology a game-changer. Signature analysis offers superior monitoring of cutting processes where material diameter fluctuates throughout the cut. As the material diameter changes, the RPM adjusts, causing sensor fluctuations that are unrelated to the tooling. Signature analysis software addresses this by learning the entire cutting path, or “signature,” using a variety of sensors. The user defines upper and lower boundaries around this signature, creating a “window” that the signature must stay within to be considered a valid cut. If the signature exceeds these boundaries, an alarm is triggered. Since this is a time-based analysis, accurate timing in relation to the cutting start time is essential. By incorporating signature analysis into CNC machining, manufacturers can expect a host of benefits, including easier programming, consistent workpiece finishes, extended tool life, and optimized machining times that result in higher throughput for operators. In manufacturing, this technology is particularly useful for facing and turning operations on a CNC lathe, where RPM adjustments maintain a proper chip load as material thickness changes. For instance, as a lathe begins cutting at the part’s original diameter and removes material, the diameter gradually decreases. This leads to RPM fluctuations that are challenging to monitor with traditional tool monitoring methods. With signature analysis integrated into CNC machines, these cuts can be closely monitored to ensure optimal surface finish by learning the cut signature and setting appropriate boundaries. “Signature analysis is not limited to constant surface speed cutting; it can also be applied to other aspects of machine tool monitoring. For instance, in cases where material is missing during a cut, traditional technologies may only detect this early in the process. Signature analysis, however, allows us to identify missing material at any point during the cut,” said Rob Caron (PE), President of Caron Engineering. [Learn More about Signature Analysis for TMAC](https://www.caroneng.com/products/signature-analysis/) ## Digital Factory Solutions --- ## [Setting Up the Building Blocks for a Digital Factory](https://www.caroneng.com/news/woodward-digital-factory) # Setting Up the Building Blocks for a Digital Factory Read the full article [here](https://www.mmsonline.com/articles/setting-up-the-building-blocks-for-a-digital-factory) ## Smart Tech Integration --- ## [Smart Technology Integration Results in Big Profits for Manufacturing](https://www.caroneng.com/news/smart-technology-integration-results-in-big-profits-for-manufacturing) # Smart Technology Integration Results in Big Profits for Manufacturing A product like Caron Engineering’s TMAC (Tool Monitoring Adaptive Control) system directly interfaces with almost any CNC machine control and utilizes a separate high-speed processor to react instantaneously to conditions and make real-time automatic corrective adjustments during cutting. TMAC monitors true spindle motor power to detect tool wear and breakage in real-time. Many systems monitor current, which is a non-linear, and therefore, can be a less accurate measurement of tool wear. TMAC learns the peak power and area under the curve (power over time) of the cutting tool and can monitor tool wear based on these parameters. Caron Engineering customers are recognizing the benefits and quick ROI of investing in their technology. **UNATTENDED OPERATION** One of Caron Engineering’s aerospace manufacturing customers had TMAC installed on five horizontal machining centers cutting titanium parts. TMAC has enabled them to get real data off the machines to show the programmers how the machines are reacting to their part programs. They have realized some very serious gains by implementing TMAC. To start, TMAC detects worn tooling during operation. Using the adaptive control feature, TMAC automatically slows the feed rate down during rough operations to keep the tool from breaking as it begins to deteriorate, allowing them to cut more parts per tool. These parts also contain a lot of air cutting. TMAC (adaptive control) automatically increases the feed rate in these areas to reduce cycle time. They no longer need to be ultra conservative with their speeds and feeds, knowing TMAC will make the necessary adjustments for them. They are seeing reductions in cycle time of 20 – 26% per machine. TMAC has also given them the confidence to run their machines overnight and during weekends, at times when there are no operators present. They can load up their pallet system and tool carousels and then walk away for the weekend. If TMAC detects a tool is worn, it will automatically call a redundant tool if it’s available in the carousel. The TMAC interrupt program will shuttle out pallets if there is an alarm, to automatically move to the next workpiece, eliminating machine downtime. They return to the shop on Monday and all parts have been cut, or the machine has stopped if TMAC has detected issues or exhausted its tooling and pallets. **PROTECT YOUR MACHINE & TOOLING** Another customer in the oil and gas industry has fully automated work cells. Unbeknownst to the customer, a robot loaded a part incorrectly into the work holding. This customer avoided a devastating crash since the machine was equipped with Caron Engineering’s TMAC system monitoring the real-time power load on the tool. TMAC immediately registered the power spike as the power load deviated from the norm, triggering an extreme alarm. With TMAC’s direct interface to the CNC control, TMAC instantly stopped the machine **before the next insert even came in contact with the material**. Without any human intervention, Caron Engineering’s TMAC system shut the spindle off in time to save all the inserts and prevent the customer from destroying the work holding. **BOOST PRODUCTION** The transportation industry is also noticing considerable gains with TMAC. A customer machining compacted graphite iron engine block components has two large identical horizontal machining centers, running the same part and process. Both machines are running 6 parts per shift. The customer implemented Caron Engineering’s TMAC system on one of the two identical HMC’s. The machine running TMAC saw an immediate cycle time reduction of 25% using the adaptive control option, automatically adjusting the feed rate through material cutting. In addition, the operators were performing multiple critical checks throughout the process. With TMAC, these manual checks were no longer needed since TMAC runs these checks in real time. By eliminating these manual checks and gaining the ability to run the machine unattended, cycle time on this part was reduced by an additional 16%. The implementation of TMAC on this machine resulted in a total cycle time savings of 41%. They are now producing 10.2 parts per shift, compared to only 6 on the identical HMC running without TMAC. This customer has since ordered nine more TMAC systems. ## New Sales Manager Appointment --- ## [Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager](https://www.caroneng.com/news/caron-engineering-welcomes-ulli-thornton-as-western-us-regional-sales-manager) # Caron Engineering Welcomes Ulli Thornton as Western US Regional Sales Manager Caron Engineering, a leading provider of tool monitoring, automation, and process control technology for manufacturing, is pleased to announce the addition of Ulli Thornton as the company’s new Western US Regional Sales Manager. With over 20 years of experience in the manufacturing industry, Thornton brings extensive expertise in sales, marketing, product management, and business de![](https://www.caroneng.com/wp-content/uploads/Ulli-e1743175080465-300x300.png)velopment to the team. Throughout her career, Thornton has been instrumental in driving regional growth and profitability, developing go-to-market strategies, and leading technical sales initiatives. She has a strong background in creating and localizing marketing content, optimizing business efforts, and supporting automation and digital manufacturing advancements. In her new role, Thornton will be responsible for expanding Caron Engineering’s presence in the Western US, developing strategic partnerships, and providing innovative solutions to support manufacturers in optimizing their CNC processes. Her leadership and industry expertise will be invaluable as Caron Engineering continues to drive innovation in smart manufacturing and process automation. “We are excited to welcome Ulli to the Caron Engineering team,” said Mike Laurendeau, National Sales Manager at Caron Engineering. “Her deep knowledge of the industry and proven track record of success in sales and marketing make her a tremendous asset to our customers and partners in the Western US.” For more information, visit: [www.caroneng.com](http://www.caroneng.com/) ## Lights-Out Machining Solutions --- ## [Automate with Confidence: Caron Engineering’s Solutions for Lights-Out Manufacturing](https://www.caroneng.com/news/lights-out-machining-solutions) # Automate with Confidence: Caron Engineering’s Solutions for Lights-Out Manufacturing Manufacturers across the globe are experiencing numerous challenges with the most predominant among them being the prevalent skills gap of potential employees, the increasing process complexity, and integrating robotics or automation systems. There is no question that manufacturers are quickly pivoting strategies, equipment, and technology to adapt to a more wholly automated future. While the expected throughput for these manufacturers continues to rise, innovative technology from Caron Engineering can address these challenges and create the ideal environment for what is known as lights-out machining. ## Caron Engineering Manufacturing Technology Achieving true lights-out machining capabilities at your facility may require the complete arsenal of Caron Engineering manufacturing technology. Each technology system is a critical component of lights-out machining solutions and successfully optimizes productivity, quality, and precision across all manufacturing sectors within your facility no matter the complexity. [TMAC (Tool Monitoring Adaptive Control)](https://www.caroneng.com/products/tmac/): Now in its third iteration, TMAC 3.0 is a tool wear and breakage detection system that delivers real-time adaptive tool monitoring and is essential to attaining lights-out machining capabilities. With a direct interface to the CNC and a dedicated high-speed data processor, TMAC takes control of the cutting process to make automatic, real-time adjustments during cutting. TMAC monitors true spindle motor power and identifies the optimum power for each tool and cutting section. This information is then compared to the user-defined limits to calculate tool wear in real time as cutting takes place to protect the machine, maximize tool life, and reduce the cycle time of complex components. TMAC automates the cutting process by allowing you to walk away, knowing it will take action if anything outside the normal cutting parameters occurs. Integrating TMAC into your manufacturing environment will avoid unplanned equipment downtime, reduce cycle time, stop detrimental events from occurring, and afford unattended cutting operations required to achieve lights-out machining. [ToolConnect](https://www.caroneng.com/products/toolconnect/): ToolConnect is a machine tool data management system capable of eliminating human error and reducing machine tool setup time by automating the transfer of presetter-measured tool data to and from the CNC control. Instead of relying on time-consuming manual data entry prone to human error, ToolConnect uses an RFID system to read and write data directly to the CNC control including the necessary tool offsets and tool life data. ToolConnect creates a uniform user interface for all CNC machines on your shop floor and provides a consistent and accurate procedural flow to automate the process of loading CNC tools, necessary for lights-out machining. [AutoComp](https://www.caroneng.com/products/autocomp/): AutoComp is a Windows-based software application capable of reading and processing part measurements from nearly any electronic gauging device. AutoComp determines the required tooling adjustments, and updates the offset settings inside the control. All of this happens automatically without requiring operator intervention that can introduce manual data entry errors, and further streamlines production by notifying operators when a tooling change is required. AutoComp ensures consistent quality of finished parts and closes the loop with automated compensation calculation and feedback to the CNC, an essential piece for lights-out machining. [DTect-IT](https://www.caroneng.com/products/dtect-it/): Caron Engineering’s DTect-IT CNC Sensor Analysis System merges high-precision machine tool sensors with an advanced analysis capability to detect and correct any anomalies that arise during the machining process. Whether you’re looking to detect and correct vibration issues, determine if a collet is clamped correctly, or have runout issues, DTect-IT offers manufacturers several analysis types to best fit their CNC machining processes, including limit analysis, spindle bearing analysis, fault detection, frequency analysis, signature analysis, and data collection analysis. With an advanced historical data viewer, DTect-IT allows companies to thoroughly analyze, compare, and identify machining trends over time to prevent unplanned downtime. [Smart Light System](https://www.caroneng.com/products/smart-light/): While a Caron Engineering Smart Light System is not a mandatory requirement for manufacturers looking to achieve lights-out machining capabilities it can be an incredibly beneficial tool. The completely customizable Smart Light System provides an immediate visual representation of the various stages, statuses, and possible complications that can arise during the operation of CNC machining equipment. This visual identification process significantly reduces the need for hands-on inspection methods that necessitate additional personnel and time. Using the CEI Smart Light System [,](https://www.caroneng.com/products/smart-light/) you can see the status of all CNC machines at a glance, allowing a single operator to effectively manage more machines simultaneously. ## Reasons To Implement Lights-Out Machining Solutions The goal of any manufacturer pursuing lights-out machining solutions is to limit human interaction throughout the manufacturing process and directly improve the overall efficiency, accuracy, and throughput of their facility. With persistent obstacles like skills gaps, complicated technology, and general availability of qualified operators or technicians, the integration of Caron Engineering technology provides manufacturers with the following advantages in their pursuit of lights-out machining solutions. **Improved Productivity & Efficiency:** All Caron Engineering technology is designed for automation to improve the productivity and efficiency of manufacturing processes to achieve lights-out machining. From the Smart Light System identifying machining stages for floor personnel to the tool-cutting optimization power of TMAC, each piece of technology will provide an immediate lift to the productivity and efficiency of your business. **Comprehensive [Monitoring](https://www.caroneng.com/products/tmac/) & Control:** All of Caron Engineering’s advancements in manufacturing technology are focused on bringing a greater sense of understanding and control throughout your facility. With user-friendly interface designs and instant accessibility, achieving a state of lights-out machining at your facility has never been easier. Manufacturers can now make immediate adjustments throughout the manufacturing process to improve efficiency metrics and meet evolving quality standards. **Cohesive Device Communication:** Establishing a comprehensive communication network across the various complex devices found in manufacturing environments is paramount to successful lights out machining. [MiConnect Technology Software](https://www.caroneng.com/robotics-integration-cnc-machining/) offers customers the capability to create a unified network that offers incredible control throughout the manufacturing process. Currently, no other available technology streamlines device communications with a singular piece of software quite like MiConnect. **[Reducing Cycle Time](https://www.caroneng.com/products/tmac/):** A primary focus for any manufacturer integrating lights-out machining solutions from Caron Engineering is reducing cycle time. By eliminating the need for continual human intervention, establishing a uniform communication network, and implementing the appropriate systems to make automatic process adjustments in real-time, manufacturers are reducing their cycle times and producing more quality components in less time. **Streamlined Labor Force:** With less manual intervention required throughout the machining process, companies can machine more material with fewer required operators. Furthermore, establishing a uniform user interface across the entire fleet of CNC equipment with MiConnect, TMAC, or ToolConnect simplifies the training of new employees. Caron Engineering technology can help manufacturers better understand their specific needs as they face labor shortages and skills gaps. **Enhanced Quality & Consistency**: The numerous analytical and information-sharing resources available through Caron Engineering are all essential to the enhanced quality and consistency paramount to successful lights-out machining operations. Companies that have successfully integrated one or several of Caron Engineering’s solutions have seen significant improvements in the quality and consistency of machined components. An excellent contributor to improved quality is [TMAC](https://www.caroneng.com/products/tmac/), as it continually monitors to keep cuts within the established thresholds while simultaneously diagnosing tool wear and taking in data from other sensors such as vibration, spindle speed, and coolant flow, to monitor other essential machining processes. CNC Machines equipped with TMAC fabricate with exceptional precision and significantly reduce the possibility of scrapped components or wasted material. **Continuous Machine Run Time:** Lights-out machining solutions expand manufacturing output beyond the standard first or second-shift hours. Caron Engineering’s proven manufacturing technology improves the trust business owners have that CNC machines can maintain strict tolerances, catalog essential data, and operate without risk of damage to material or machines after normal operating hours. Not only that but continual machine run-time separates manufacturers from the competition and allows greater throughput and reduced costs without risking final component quality. ## ![SpiderCool Automation with MiConnect_Caron Engineering](https://www.caroneng.com/wp-content/uploads/SpiderCool-Automation-with-MiConnect_Caron-Engineering.png) ## Finding An Integrator of Caron Engineering Technology Caron Engineering recognizes the importance of offering highly qualified integration services for our smart manufacturing technology to companies pursuing lights-out machining solutions. That is why we’ve established a [comprehensive international network](https://www.caroneng.com/integrators/) of qualified companies that specialize in the integration of our technology. Their intricate understanding of TMAC, AutoComp, DTect-IT, ToolConnect, MiConnect, and Smart Light Systems will immediately upgrade the efficiency and operational capacity of your business as you progress towards lights-out machining. Streamline and stress-free integration into your CNC systems ensures that your facility operates at optimal performance levels before, during, and after the cut while providing the confidence you need to move towards around-the-clock machining. [\[Contact Caron Engineering to Learn More About Lights-Out Machining Solutions\]](https://www.caroneng.com/contact/) ## Check out these lights-out machining cells by Caron Engineering ## MiConnect Technology --- ## [New Streamlined Application Builder for Manufacturers](https://www.caroneng.com/news/introducing-miconnect-technology-for-manufacturing) # New Streamlined Application Builder for Manufacturers Programming for custom automation solutions and communication for CNC related processes has always been very challenging and machine-specific due to customized coding and unique rigid infrastructure. Well, Caron Engineering’s new software innovation intends to make programming custom manufacturing applications that much simpler. MiConnect Technology powers solutions such as, direct interfacing for automation systems to communicate with the CNC control, extracting any required information from the CNC, inputting external devices (such as RFID, barcode, files), reading and writing system parameters, parsing and extracting data, controlling human process interaction, minimizing operator decision making, and adding systemized securities. Perhaps you need to verify the operator has successfully loaded the correct tooling or to export probe data from a part program. Maybe you want to completely remove any operator interaction from a production cell and have it run lights out. MiConnect Technology is the solution. Once designed and implemented by our integration specialists, this sophisticated technology allows manufacturers to control their processes by directing the user through the proper operational steps and has the fast capability of extracting any necessary data from the CNC. The inherent audit log records every step, action and data exchange which is logged with a date and time stamp. This data is available locally or via MTConnect and is valuable for quality control and process verification. The intelligible HMI is designed to guide the user through any required steps and confirm successful completion before advancing to the next step of the manufacturing process. Screens can be added to show messages and confirmations to better assist the operator through the interaction. _“MiConnect Technology was developed to streamline processes for an advanced manufacturing environment. The variety of CNC machines, automation systems, and useful data is unique to each manufacturer’s operations. Prior to MiConnect, programming these devices to communicate and extracting unique datasets, or guiding and verifying operator processes required excessive coding time and customization. Furthermore, if the programs ever needed to be adjusted, it relied on the original programmer to make these corrections. In an ever-growing age of automation, MiConnect is the essential tool kit to build custom applications in a fraction of the time,_” said Rob Caron, PE, President of Caron Engineering. ###### [➡️ Learn more about MiConnect Technology!](https://www.caroneng.com/miconnect-technology/) ## Surface Roughness Analysis --- ## [In-Process Surface Roughness Analysis for CNC Machined Parts](https://www.caroneng.com/news/in-process-surface-roughness-analysis) # In-Process Surface Roughness Analysis for CNC Machined Parts Caron Engineering has added in-process surface roughness measurement to the suite of applications for their [DTect-IT](https://www.caroneng.com/products/dtect-it/) product. DTect-IT is a versatile CNC sensor analysis system that takes in data from a multitude of high-precision sensors. The surface roughness measurement application uses the [Blum-Novotest](https://www.caroneng.com/products/blum-novotest/) TC64 RG Digilog Probe as the sensor input in DTect-IT to analyze the surface of a part. ![Roughness Detection](https://www.caroneng.com/wp-content/uploads/Roughness-Detection_Caron-Engineering-1-300x300.png) Surface roughness measurement verifies the surface finish result of the machined part. The ability to have automated in-machine surface roughness measurement gives manufacturers the fast capability to measure every part for optimum finish. This technology also gives insight to cutter health by looking at the surface finish each time a tool cuts. For the analysis, the CNC program scans the surface of a part with the probe stylus. The TC64 probe uses a 10um radius tip to provide high-resolution scanning. The DTect-IT software collects the scanned data from the probe, and using NIST traceable algorithms, calculates the surface roughness. The roughness report is displayed on the DTect-IT HMI (Human Machine Interface) immediately following the probe scan. DTect-IT handles all required filtering and allows the user to set scanning parameters based on the type of surface finish being measured. Results can be metric or imperial and include Ra, Rz, Rsm and Rmax. “Before this technology became available, the only way to measure surface finish was to remove the part and use a special surface roughness gauge which proved both time-consuming and challenging to accurately measure all surfaces of the part. This new technology allows in-machine measurement, and because the probe can be oriented to any angle, it can scan any surface the machine can access”, said Rob Caron, President of Caron Engineering. ## Smart Technology Showcase --- ## [Caron Engineering Demonstrates New Technology at IMTS 2022](https://www.caroneng.com/news/caron-engineering-demonstrates-new-smart-technology-for-lights-out-machining-at-imts-2022) # Caron Engineering Demonstrates New Technology at IMTS 2022 At IMTS 2022, Caron Engineering will feature their latest technologies for automation, cycle time reduction, unmanned operations, and total process monitoring and control for tool loading, offset adjustment, and more. With their technology outfitted on a Tsugami TMA8 live-cutting demo, they will showcase a fully automated (lights-out) manufacturing process in booth 135736. The highlighted Caron Engineering technology will include: - **ToolConnect:** Before cutting, Caron Engineering’s tool data management system, ToolConnect, will automate the process of loading tools into the machine. ToolConnect reads and processes data from presetter written RFID tags, and 2D printed barcode tags to automatically update tool information directly to the CNC control, a![](https://www.caroneng.com/wp-content/uploads/IMTS-2022_Caron-Engineering-300x145.png)nd further prevents a wrong tool from being loaded into the machine. - **TMAC:** During cutting, their adaptive tool monitoring system, TMAC, will measure tool wear and detect breakage in real-time, while simultaneously monitoring tool and spindle vibration. Using the live cutting data, its adaptive control feature will optimize the process by adjusting feed rates to reduce cycle time up to 60%. - **DTect-IT Software** will extract data from a Blum Scanning probe to analyze the surface of the part and determine any dimensional anomalies, for consistent part quality. - **Blum LC50 Digilog** laser will measure the rotating tools on the machine using the state-of-the-art Digilog technology which provides advanced tool measuring and analysis. - **MiConnect Technology:** Their latest innovation, by way of its flowchart style programming, will control the interaction between the CNC control, a Universal Robot and a Sylvac Scan25 vision gauge. - **AutoComp Software** will automatically process the measurement data from the vision gauge to calculate and compensate offsets in the control. AutoComp eliminates human error by statistically controlling tool offsets. Caron Engineering’s products are unique in the fact that they can interface with nearly any CNC machine tool on the market, and be customized for almost any application. Their high precision sensors are infinitely scalable to accommodate all types of cutting. These solutions run standalone or work together to successfully remove operator error and confidently run unattended operations. ## Barcode Tool Setup --- ## [Streamlining Tool Setup with Barcode ID Integration in ToolConnect](https://www.caroneng.com/news/new-barcode-id-integration-with-caron-engineerings-toolconnect-system) # Streamlining Tool Setup with Barcode ID Integration in ToolConnect The ToolConnect barcode application uses a barcode scanner at the machine tool to scan the presetter generated barcode. ToolConnect reads and processes the barcode data, displays all tool and process information and then automatically updates the offsets to the correct fields in the control. No operator data entry is required. In addition to displaying and verifying the tool information on the screen, ToolConnect guides the user through each step of the process to further automate and prevent error. The user screens can prompt the operator through tasks, such as (1) scan the barcode, (2) confirm the tool information, (3) open the carousel door, (4) insert the tool into the (automatically indexed) position, (5) close the door, and other possible scenarios a user requires. The offsets will not be sent to the CNC control until ToolConnect has verified the correct tool is loaded into the machine and each customer-defined step in the process is successfully executed. With ToolConnect, the system is designed to fit the users’ tool load specifications. This includes customized user screens, process flow, initial setup and system checks, and general access to the system. The system is flexible and can accommodate changes at any time. Additionally, ToolConnect has an audit log that records every step, action and data exchange, marked with date and time stamp. This data is available locally or via MTConnect; used for quality control and process verification. A presetter is an extremely valuable and accurate device for measuring your tools offline. Using ToolConnect in combination takes this measurement data directly to the offset table in the CNC. This eliminates error associated with manual data entry and automates the tool load process. The universal machine tool compatibility of ToolConnect provides a common interface across all machines on your shop floor, increasing operator efficiency. Adding the barcode scanning capability to ToolConnect provides a more affordable option for customers who do not need the extensive capabilities of the more robust and continuously reusable RFID system. Visit the links below to learn more: ToolConnect Website Page: [ToolConnect Page](https://www.caroneng.com/products/toolconnect/) ToolConnect Demo Video: [https://youtu.be/cwy3SJfvy0c](https://youtu.be/cwy3SJfvy0c) ## Tool Wear Detection --- ## [TMAC Delivers Precise Tool Wear Monitoring and Data-Driven Analysis](https://www.caroneng.com/news/advanced-tool-wear-detection-and-analysis-with-tmac-3-0) # TMAC Delivers Precise Tool Wear Monitoring and Data-Driven Analysis Caron Engineering’s adaptive tool monitoring system, TMAC, measures true motor power as the tool cuts through material to determine if a tool is worn or broken. Static limits based on the learned power of the tool in cut will alarm the machine when not enough power is achieved (no contact with material) or when too much power is achieved (tool is worn or broken). This method protects the machine and tooling; however, it is not always the most precise determination of how the tool is wearing over time. **Power over time.** Caron Engineering’s TMAC system has a work enable option for each tool and section to accurately monitor tool wear by measuring power over time. To do this, TMAC learns the total power consumption for each tool in cut. The learned work is marked against user-defined (wear) parameters to accurately measure tool wear in real-time, as the tool is cutting. As tools gradually begin to fail due to regular operation, the power consumption over time will increase until a wear percentage alarm is triggered. In most cases, when a wear alarm is generated, TMAC will allow the cut to finish and then safely retire the tool. This feature can also prevent nuisance alarms that might generate a small power spike to trigger an alarm. It is also a much more accurate method to determine undercut conditions. **Safeguard the machine.** By using direct communication to the CNC control and measuring tool wear using a high precision power sensor that measures at 200x per second, TMAC is able to react instantly to wear and extreme conditions. Inconsistencies in tooling and material are imminent. If TMAC registers a power spike, indicating a tool has broken during cutting, it will automatically stop the machine and retract the tool before damage can occur. For unattended operations, when worn tools are detected, TMAC can call redundant tooling to keep the operations running smoothly 24/7. **Feed rate optimization.** TMAC also has an adaptive control feature that takes control of the machine tool feed rate in real-time. TMAC learns the target power as the tool cuts through the material and then automatically adjusts the feed rate to optimize the cut. TMAC increases the feedrate through low power cuts and decreases the feed rate through high power cuts and as tools wear. Typical cycle time savings, especially with difficult-to-machine hard and composite materials, is up to 60% (even more in some cases). As a tool wears, the feed rate to maintain a constant power level must be reduced. This feed rate reduction can be used to trigger a wear limit, as an additional method to determine tool wear. **The Data.** TMAC saves and records all cutting data. This is incredibly useful to compare how tools wear over time. TMAC data allows the user to interrogate specific areas of the cut to look at anomalies in the normal cutting operation. If a tool uses inconsistent power over the same cut, the user can overlay these cuts to see what is causing any anomaly. This information can also give TMAC users insight into tool life comparison between different tooling vendors and regrinds. “Using the TMAC work feature to monitor the power consumption of the tool over time, we can more precisely measure how the tool is wearing, allowing tools to be used to their maximum life. By accurately monitoring tools with high resolution sensors and then seeing a graphical representation of the cutting, the user can diagnose problems much faster and with greater confidence,” said Rob Caron, President of Caron Engineering. [Learn More About TMAC 3.0](https://www.caroneng.com/products/tmac/) ## Error-Free Tool Control --- ## [Achieve Precision with Automated Tool Offset Adjustments Using AutoComp](https://www.caroneng.com/news/error-free-tool-offset-control-with-caron-engineerings-autocomp-software) # Achieve Precision with Automated Tool Offset Adjustments Using AutoComp Caron Engineering’s AutoComp software delivers error-free tool offset control. AutoComp is a Windows based software application that processes data from almost any electronic gauging device and updates the tool offsets automatically in the CNC control. All Caron Engineering products interface directly with most CNC controls to optimize machining. AutoComp is doing just that by closing the loop for many manufacturing cells and eliminating costly data-entry errors at the same time. So, how does it work? (1) The part is machined. (2) The part is measured using almost any electronic gauging device (i.e. wireless calipers, laser micrometers, CMM’s, vision systems, etc.). (3) AutoComp reads the measurement file and compares the data to user programmed compensation limits to determine if compensation is required. (4) AutoComp automatically adjusts tool offsets in the CNC control. During setup, the user creates an AutoComp routine consisting of the essential part dimensions and inputs the parameters (tolerances and compensation limits) for each dimension. AutoComp reads the measurement file and checks each measurement against the feature limits to calculate the correct amount to offset each tool. AutoComp sends this information to the CNC control automatically, with no operator intervention required. The built-in PartView feature allows the user to upload a (jpg) picture and visibly associate each area of the part being measured for deviation. The operator can more easily identify which area of the part will be compensated. The measurement blocks are highlighted to clearly see at a glance if the part measurement is good (green), requires compensation (yellow), or is out of tolerance (red). AutoComp also has the ability to track tool wear and report when a tool change is needed. Each time a tool is compensated, the amount of compensation is saved. When tool compensation has exceeded a user-defined threshold, a wear limit is issued informing the operator that the tool needs to be changed. AutoComp can alsosignal the CNC control to automatically call a redundant tool or stop the machine. All measurement and compensation data are saved to a file. The data is date and time stamped for future analysis. Additionally, the operator receives real-time status of the useful life for each tool. AutoComp enables automatic tool wear compensation that maintains part accuracy and eliminates human error, thereby improving product quality and reducing scrap. [Learn More About AutoComp](https://www.caroneng.com/products/autocomp/) ## Tool Monitoring Solutions --- ## [Enhance Drilling and Tapping Accuracy with Caron’s Tool Monitoring Solutions](https://www.caroneng.com/news/tool-monitoring-drilling-and-tapping-operations) # Enhance Drilling and Tapping Accuracy with Caron’s Tool Monitoring Solutions Using a high precision, auto-scaling power sensor, TMAC measures the load on the tool and compares it to the user-defined limits to determine wear. TMAC’s direct interface to the CNC control allows the system to make real-time adjustments to feeds and speeds, automatically expire worn tools, and stop and retract tools instantaneously in the event of breakage or other extreme conditions. All of this is driven by an intuitive user interface to view all live cutting data as it happens, with all cuts recorded to view and analyze at any time. “One operation our TMAC customers are typically surprised we can monitor so accurately is tapping cycles. Rigid tap cycles are notoriously difficult to monitor because of all the power spikes caused by the forward and reverse actions of the tool. Monitoring tapping cycles are very simple to set up through use of time increments in TMAC,” explains Paul Sevin, Technical Product Specialist for Caron Engineering. TMAC learns the power of the tap as it winds into the materials. During monitoring, TMAC can isolate just the cutting portion of the tap (in its forward cutting motion). As the tap unwinds from the material, the monitoring goes into a “hold mode”, ignoring any spikes in data. TMAC measures the wear of the tool and alarms the machine when excessive wear or breakage occurs using either tool wear linear or area under the curve limits. Use of a pre-load signal creates precise start and stop timing from the CNC which synchronizes monitoring based on specific PLC (programmable logic controller) functions. TMAC will ignore unwanted power spikes due to reversing the tap and unwinding out of material. “One of our customers is drilling and tapping a tombstone loaded with 16 parts, with 5 holes per part. The customer is successfully monitoring the drilling and tapping of 80 holes with time increments in TMAC. TMAC measures the power required to drill and tap the hole, ensuring that enough power is achieved to complete each operation. This is especially important prior to tapping, to make sure each hole was successfully drilled,” said Paul Sevin. By using high precision power sensors, TMAC can monitor a wide range of taps. With smaller taps, the auto-scaling sensor capabilities make it possible to register even the slightest power signals and monitor all cutting operations. With the newest version of TMAC (version 3.0), users can even label the cuts as specific features on the part. [LEARN MORE ABOUT TMAC 3.0](https://www.caroneng.com/products/tmac/) ## CNC Machine Monitoring --- ## [Safeguard CNC Operations with Caron Engineering’s Sensor Analysis Technology](https://www.caroneng.com/news/dtect-it-sensor-and-software-suite-capable-of-various-machine-monitoring-applications) # Safeguard CNC Operations with Caron Engineering’s Sensor Analysis Technology DTect-IT has become even more versatile since its inception, now capable of communicating with multiple sensors, including vibration, strain (to measure force), high precision power, and analog (which allows connecting _any_ sensor with a 0 to ± 10 VDC analog signal, and 4 – 20 mA current signals). DTect-IT software has multiple analysis options allowing the user to monitor and scrutinize sensor data in various ways. Using limit analysis, the user can set limits to monitor any of the compatible sensors. DTect-IT has a new learn mode to automatically set limits based on the acquired (learned) sensor data or limits can be set manually using adjustable sliders. When a defined limit has been met or exceeded, alarms and notifications occur. Barfeeder vibration detection has been a widely used application with limit analysis. By attaching a vibration sensor to the barfeeder, limits can be set to detect excessive vibration levels due to imperfections in the bar. DTect-IT can signal the CNC to reduce spindle RPM until the vibration levels are acceptable to make good parts or even stop the machine if extreme vibration levels are detected. This application is greatly reducing scrap rates and decreasing spindle damage due to excessive vibration by detecting and compensating for imperfections in real-time instead of machining a whole (bad) bar of parts. With bearing analysis, DTect-IT analyzes the velocity and acceleration signatures of a vibration sensor (attached to the spindle) to monitor spindle bearing health. Results are displayed within 5 seconds, and reports are automatically generated and saved for future analysis. Using the built-in data viewer, users can trend bearing data over time to establish maintenance schedules. Fault detection analysis can be used with any sensor to identify an excessive condition, such as machine impact, overheating, extreme vibration, etc. DTect-IT recognizes when upper and lower limits are exceeded and records data on either side of the fault for analysis. The newest analysis option with DTect-IT is frequency analysis. DTect-IT can monitor the frequency levels of any sensor and set magnitude limits to monitor and detect anomalies within specific frequency bands. Alarms and notifications are generated when magnitude limits (in decibels) are exceeded. The combination of sensor options and analysis options (of which multiple can be run simultaneously for each sensor), make the applications for this product almost limitless. Many of the more prominent applications, include the abovementioned barfeeder vibration detection and bearing analysis, but DTect-IT is also widely used to for tool wear and breakage detection, yoke strain detection, tapping operations, coolant and temperature monitoring, machine health, preventative maintenance, and more. DTect-IT offers a lot of functionality and features ideal for a smart manufacturing environment. It is best for monitoring up to four tools. It can run as a standalone application or easily connects to the CNC to command start and stop variables. DTect-IT can set sensor levels and alarms with variables that can be used by the CNC part program to make adjustments. DTect-IT has a data collection analysis to collect raw data from any sensor (up to 62,500 data points/sec). The latest release of DTect-IT includes a new analysis viewer. All monitored data is stored and can be accessed via the DTect-IT Viewer for inspection, review, and analysis. The MTConnect compatibility allows users to interrogate sensor information on various levels and provides seamless communication with shop floor automation systems. [Learn More About DTect-IT](https://www.caroneng.com/products/dtect-it/) ## Bar Feeder Vibration Detection --- ## [Manufacturing News](https://www.caroneng.com/news/manufacturing-news-bar-feeder-vibration-detection-with-caron-engineerings-dtectit) # Manufacturing News \| Caron Engineering’s DTect-IT Reduces Scrap Monitoring Bar Feeder Vibration Read the full article [here](https://mfgnewsweb.com/archives/4/48516/Quality-Control-mar17/Bar-Feeder-Vibration-Detection.aspx) ---