Tool Monitoring Adaptive Control

Our Tool Monitoring Adaptive Control (TMAC) system protects your CNC machine while providing valuable information about your cutting process. TMAC reduces the high costs associated with broken tools, lost production, and rejected parts by effectively measuring tool wear in real time. It operates on the principle that the power required to cut a part increases as the tool’s cutting edges deteriorate.

The “Adaptive” control feature of TMAC reduces cycle time and optimizes cutting time under changing cutting conditions to improve tool life.


TMAC maximizes tool life by monitoring true power, not guessing with cycle count or time in cut.

  • Protects your CNC machine and tools
  • Determines when tools are worn or broken
  • Immediate machine stop and retract when a tool breaks to minimize damage
  • Remote notification of machine alarms
  • Scalable sensitivity for more accurate sensor resolution
  • Real-time data viewer
  • Click on any point in the viewer to inspect CNC axis positions and program line number
  • Time stamps all monitored events
  • Graphical display of cutting data for analysis
  • Excellent for unattended operation


Adaptive Control regulates feedrates to maintain a constant spindle motor power for optimum cutting and reduced cycle time. TMAC automatically increases the feedrate with low power conditions, and decreases the feedrate with higher power cuts and as tools wear.

  • Automatically adjusts the feedrate for each tool to maintain a constant power in the cut
  • Eliminates the need for manual adjustment
  • Allows the tool to always cut at its optimum power and feedrate
  • Adjusts for varying cutting conditions
  • Potential cycle time savings of 20% – 60%
  • Reduces cost of consumable tooling by increasing tool life
  • Calculates tooth pass frequency to adapt to slow RPM cutters (under 1000 RPM)
  • Adjusts feedrates smoothly versus CAD/CAM programs that can only adjust per line in the program

For Multi-Tasking Machines

  • Monitors multiple paths simultaneously
  • Can be equipped with micro tool sensors to monitor very small tools
  • Uses accelerometers to monitor machine and tool vibration
  • Includes several additional applications to allow easier setup and unattended operation
  • Adaptive control for each process


Additional Sensor Options

Vibration Sensors
Micro Sensor Tools
Coolant Flow
Spindle Speed
Coolant Pressure


A single axis sensor capable of measuring vibration to 22KHZ at 64KPS. This sensor has adjustable sensitivity and is typically used to measure tool condition and machine health monitoring.

They can be used to:

  • Monitor the machine for impact
  • Record bearing vibration
  • Determine excessive bar feeder vibration


A strain gauge sensor that is embedded in a tool holder to allow the monitoring of very small tools in a static swiss-type holder. Examples are drills, boring bars, and turning tools.


Monitors coolant flow. Available for a wide variety of coolant flow and pressure levels.


Accepts input from a spindle encoder or proximity switch to accurately measure spindle speed independent of the CNC control.



Measures coolant pressure in real time and allows graphing of all data. Alarms if out of specification.



TMAC monitors spindle bearing health.  A CEI vibration sensor is attached to the spindle, hardwired to TMAC, and the bearing analysis is initiated in the CNC part program.  Results are displayed within 5 seconds and TMAC saves reports to a file for analysis.  The vibration signal is analyzed for acceleration to detect the health of the bearings, and velocity to detect misalignment, imbalance, and looseness.


Other companies have data collection systems that can look at TMAC and analyze the data in real time.  These OEE applications integrate with TMAC allowing the user to easily view the status of all TMAC systems on a shop floor.  So, you’ll always know what your machines are doing.