In the Process Monitoring workspace the control visualizes the machining process during program run. You can activate various monitoring tasks that are relevant to the process. If necessary, you can adapt the monitoring tasks.
Application
Requirements
- Process Monitoring (software option 168)
- Monitoring sections defined with MONITORING SECTION
- Possible without limitation in the FUNCTION MODE MILL machining mode
Defining monitoring sections with MONITORING SECTION (option 168)
The monitoring tasks FeedOverride and SpindleOverride are functional in the FUNCTION MODE TURN machining mode (option 50).
Functionality
The Process Monitoring workspace provides information and settings for monitoring the machining process.

- Depending on the cursor position in the NC program, the control provides the following areas:
- Global area
- Strategy range
- Monitoring options column in the global range
- Monitoring options column within a monitoring section
The control shows information about the active NC program.
The control shows the monitoring tasks and the graphs of the recordings. You can configure settings for the monitoring tasks.
The control displays information on the recordings that relate to all monitoring sections of the NC program.
Monitoring options column in the global range
The control displays information on the recordings that relate only to the currently selected monitoring section.
Icons
The following icons are shown in the Process Monitoring workspace:
Icon | Meaning |
---|---|
Show or hide the Monitoring options column | |
Remove monitoring task | |
Add monitoring task | |
Open settings
Settings for the Process Monitoring workspace Settings for NC program window | |
Show or hide warning and error limits If you show the warning and error limits, the control shows the monitored signal in relation to the defined limits.
If the current machining operation is at the bottom line, the current machining operation corresponds to the reference. This line shows the warning limit. If the current machining operation exceeds the middle line, the current machining operation deviates by half the set limit of the reference. This line shows the error limit. If the current machining operation exceeds the upper line for a defined hold time, the monitoring task triggers a defined response, e.g. NC stop. If you hide the warning and error limits, the control shows an absolute display of the monitored signal. The dashed lines represent the upper and lower error limits, i.e. the tunnel width. |


Global area
If the cursor is outside a monitoring section in the NC program, the Process Monitoring workspace displays the global range.
The Process Monitoring workspace shows the following in the global range:
1 | Monitoring options icon |
2 | Settings icon for the Process Monitoring workspace |
3 | Table with notes on the active NC program |
4 | Delete hints button You can use the Delete hints button to empty the table. |
5 | Information that this area is not monitored in the NC program |
Notes on the NC program
In this area, the control shows a table with information about the active NC program. The table contains the following information:
Column or symbol | Meaning |
---|---|
Type | In the Type column, the control shows different types of notifications. |
Information, e.g. the number of monitoring sections | |
Warning, e.g. if a monitoring section has been removed | |
Error, e.g. if you should reset the recordings If you make changes within a monitoring section, that monitoring section can no longer be monitored. Therefore, you should reset the recordings and set new references so that machining is monitored again. | |
You can sort the table by information type by selecting the Type column. | |
Description |
|
Program line | If the information depends on an NC block number, the control displays the program name and the NC block number. |
Strategy range
If the cursor is inside a monitoring section in the NC program, the Process Monitoring workspace displays the strategy range.
The Process Monitoring workspace shows the following in the strategy range:
1 | Monitoring options icon |
2 | Settings icon for the Process Monitoring workspace |
3 | Settings icon for the monitoring tasks |
4 | Show or hide warning and error limits |
5 | Monitoring tasks |
6 |
If AS is defined in the NC program with the optional syntax element, the control displays the name. If no name is defined, the control displays MONITORING SECTION. Start and end of the monitoring section in the NC program |
Strategy template
A strategy template includes one or more monitoring tasks, including the defined settings.
You can choose between the following strategy templates using a selection menu:
Strategy template | Meaning |
---|---|
MinMaxTolerance |
Monitoring task MinMaxTolerance Monitoring task SpindleOverride |
StandardDeviation |
Monitoring task StandardDeviation Monitoring task SpindleOverride |
User-defined | In this strategy template, you can compile the monitoring tasks yourself. |
If you modify a strategy template, you can overwrite the modified strategy template by clicking the Save strategy as template button. The control overwrites the currently selected strategy template.
Since you cannot restore the as-delivered state of the strategy templates yourself, only overwrite the User-defined template.
The machine manufacturer can use the optional machine parameter ProcessMonitoring (no. 133700) to restore the as-delivered state of the strategy templates.
In the settings of the Process Monitoring workspace, you can define which strategy template the control selects by default after creating a new monitoring section.
Monitoring tasks
You can change the settings and responses of the monitoring tasks for each monitoring section. You can also remove a monitoring task for a monitoring section or add one using the plus sign.
- The Process Monitoring workspace contains the following monitoring tasks:
- MinMaxTolerance
- StandardDeviation
- SignalDisplay
- SpindleOverride
- FeedOverride
With MinMaxTolerance, the control monitors whether the current machining operation is within the range of the selected references including the percentage deviation.
Monitoring task MinMaxTolerance
With StandardDeviation, the control monitors whether the current machining operation is within the range of the selected references, including expansion by the factor σ.
Monitoring task StandardDeviation
With SignalDisplay, the control shows the process progress of all selected references and the current machining operation.
With SpindleOverride, the control monitors changes to the spindle override by the potentiometer.
Monitoring task SpindleOverride
With FeedOverride, the control monitors changes in the feed override by the potentiometer.
The values of the monitoring tasks set in the as-delivered state are considered recommended output values, which you can adapt if necessary in special machining situations.
In each monitoring task, the control shows the current processing and the selected references as a graph. The time axis is specified in seconds.
Monitoring task MinMaxTolerance
With MinMaxTolerance, the control monitors whether the current machining operation is within the range of the selected references including the percentage deviation.
The percentage deviation takes into account the tool wear.
- The application cases of MinMaxTolerance are significant process faults, e.g. during small series production:
- Tool breakage
- Missing tool
- Changed position or size of the workpiece blank
The control requires at least one recorded machining operation as a reference. If you do not select a reference, this monitoring task is inactive and does not draw a graph.
1 | First good reference | |
2 | Second good reference | |
3 | Third good reference | |
4 | Limits consisting of the tunnel width | |
5 | Limits consisting of a percentage expansion of the tunnel width |
Records of monitoring sections
If, for example, you have a recording that is only just acceptable due to tool wear, you can also use an alternative application with this monitoring task.
Settings for MinMaxTolerance
- You can use sliders to configure the following settings for this monitoring task:
- Accepted percentage difference
- Static tunnel width
- Hold time
Percentage expansion of tunnel width
Upper and lower limits, based on references
Maximum time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control triggers the defined response of the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Issue warning message
- Stop NC program
- Lock current tool
If the signal exceeds the limits for the defined hold time, the control shows a warning in the notification menu.
Message menu on the information bar
If the signal exceeds the warning limits for the defined hold time, the control stops the NC program.
If the signal exceeds the warning limits for the defined hold time, the control blocks the tool in the tool management.
Alternative application with acceptable reference
If the control has recorded a machining operation that is only just acceptable, you can use an alternative application of the monitoring task MinMaxTolerance.
- Select at least two references:
- An optimal reference
- A reference that is only just acceptable, e.g. showing a higher signal of the spindle load due to tool wear
The monitoring task checks whether the current machining operation is within the range of the selected references. For this strategy, select no deviation or a low percentage deviation, since the tolerance is already given by the different references.
1 | Optimal reference | |
2 | Reference only just acceptable | |
3 | Limits consisting of the tunnel width |
Monitoring task StandardDeviation
With StandardDeviation, the control monitors whether the current machining operation is within the range of the selected references, including expansion by the factor σ.
- The application cases of StandardDeviation are process faults of all kinds, e.g. during series production:
- Tool breakage
- Missing tool
- Tool wear
- Changed position or size of the workpiece blank
The control requires at least three recorded machining operations as a reference. The references should include one optimal, one good and one acceptable machining operation. If you do not select the required references, this monitoring task is not active and does not draw a graph.
Records of monitoring sections
1 | Optimal reference | |
2 | Good reference | |
3 | Reference only just acceptable | |
4 | Limits consisting of the tunnel width | |
5 | Limits consisting of the expansion of the tunnel width multiplied by factor σ |
Settings for StandardDeviation
- You can use sliders to configure the following settings for this monitoring task:
- A multiple of σ
- Static tunnel width
- Hold time
Expansion of the tunnel width multiplied by factor σ
Upper and lower limits, based on references
Maximum time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control triggers the defined response of the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Issue warning message
- Stop NC program
- Lock current tool
If the signal exceeds the limits for the defined hold time, the control shows a warning in the notification menu.
Message menu on the information bar
If the signal exceeds the warning limits for the defined hold time, the control stops the NC program.
If the signal exceeds the warning limits for the defined hold time, the control blocks the tool in the tool management.
Monitoring task SignalDisplay
With SignalDisplay, the control shows the process progress of all selected references and the current machining operation.
You can compare whether the current machining operation corresponds to the references. This allows you to visually check whether you can use the machining operation as a reference.
The monitoring task does not respond.
Monitoring task SpindleOverride
With SpindleOverride, the control monitors changes to the spindle override by the potentiometer.
The control uses the first recorded machining operation as a reference.
Settings for SpindleOverride
- You can use sliders to configure the following settings for this monitoring task:
- Accepted percentage difference
- Hold time
Accepted deviation of the override in percent compared to the first recording
Maximum time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control triggers the defined response of the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Issue warning message
- Stop NC program
If the signal exceeds the limits for the defined hold time, the control shows a warning in the notification menu.
Message menu on the information bar
If the signal exceeds the warning limits for the defined hold time, the control stops the NC program.
Monitoring task FeedOverride
With FeedOverride, the control monitors changes in the feed override by the potentiometer.
The control uses the first recorded machining operation as a reference.
FeedOverride settings
- You can use sliders to configure the following settings for this monitoring task:
- Accepted percentage difference
- Hold time
Accepted deviation of the override in percent compared to the first recording
Maximum time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control triggers the defined response of the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Issue warning message
- Stop NC program
If the signal exceeds the limits for the defined hold time, the control shows a warning in the notification menu.
Message menu on the information bar
If the signal exceeds the warning limits for the defined hold time, the control stops the NC program.
Settings for the Process Monitoring workspace

General
- In the General area, select which strategy template the control uses as the default:
- MinMaxTolerance
- StandardDeviation
- User-defined
Graph
In the Graph area, you can select the following settings:
Setting | Meaning |
---|---|
Simultaneously plotted references |
If more references are selected than the control is to display, the control displays the last selected references as a graph. |
Preview [s] | The control can run a selected reference as a preview during processing. The control shifts the time axis of the machining operation to the left.
|
Monitoring options column
The Monitoring options column shows the following in the upper area regardless of the cursor position in the NC program:
1 | Switch for activating or deactivating process monitoring for the entire NC program |
2 | Path of the current NC program |
3 | Open the Settings icon in the Settings for NC program window |
4 | Checkbox for activating or deactivating the responses of all monitoring sections in the NC program |
- Depending on the cursor position in the NC program, the control provides the following areas:
- Monitoring options column in the global range
- Monitoring options column within a monitoring section
You can select references that are effective for all monitoring sections of the NC program.
Monitoring options column in the global range
You can define settings and select references that apply to the currently selected monitoring section.
Monitoring options column in the global range
If the cursor is outside a monitoring section in the NC program, the Process Monitoring workspace displays the Monitoring options column in the global area.
In the global area, the control displays a table with the records of all monitoring sections of the NC program.
Monitoring options column within a monitoring section
If the cursor is inside a monitoring section in the NC program, the Process Monitoring workspace displays the Monitoring options column within the monitoring section.
If the cursor is within the monitoring section, the control will leave this area gray.
The Monitoring options column displays the following within the monitoring section:
1 |
If AS is defined in the NC program with the optional syntax element, the control displays the name. If no name is defined, the control displays MONITORING SECTION. Start and end of the monitoring section in the NC program |
2 | Checkbox for activating and deactivating the responses in the monitoring section You can activate or deactivate the responses of the currently selected monitoring section. |
3 | Table with the recordings of the monitoring section The recordings refer only to the monitoring section in which the cursor is currently located. |
4 | Selection menu for the process heat map You can display a monitoring task as a process heat map in the Simulation workspace. Component Monitoring with MONITORING HEATMAP (option 155) |
Records of monitoring sections
The contents and functions of the table with the recordings of the machining operations depend on the cursor position in the NC program.
The table contains the following information about the monitoring section:
Column | Information or action |
---|---|
Reference | If you activate the checkbox for a table row, the control uses this recording as a reference for the corresponding monitoring tasks. If you activate multiple table rows, the control uses all selected rows as references. If you select multiple references with greater deviation, the tunnel width also increases. You can select up to ten references at a time.
The reference only applies to the currently selected monitoring section. The control shows a dash in the global range in this table row for information. If a table row is marked as a reference in all strategy areas or in the global area, the control displays a check mark. The reference applies to all monitoring sections of the NC program. Mark recordings that have a provided satisfactory result, such as a clean surface, as a reference. You can only select a recording of a complete machining operation as a reference. |
Date | Date and time of program start of each recorded machining operation If you select the Date column, the control sorts the table by date. |
Sync | Quality of synchronization
If the potentiometer position of the feed rate override deviates from the reference machining process, the quality becomes worse. If the path of the tool center point TCP deviates from the reference machining operation, the quality becomes worse. The first row of the table is the reference for the quality of the following table rows. Tool center point (TCP, tool center point) If the quality is between 70% and 80%, the processing operation is still OK. You should manually check the recording in this area. |
Delete | If you select the trash can icon, the control deletes the table row.
You delete all recordings including the first in the Settings for NC program window. Only in the global area |
Note | In the Note column, you can enter notes about the table row. |
Tool name | |
R | |
DR | Delta value of the tool radius from the tool management Only within the monitoring section |
L | |
CUT | Number of cutting edges of the tool from the tool management Only within the monitoring section |
CURR_TIME | Tool life from the tool management at the start of the respective machining operation Only within the monitoring section |
Settings for NC program window

- The Settings for NC program window provides the following settings:
- Reset Process Monitoring settings
- Delete all records, including the first table row
- Select the maximum number of recordings of machining operations in the table:
- Limit to 5 recordings
- Limit to 10 recordings
- Limit to 50 recordings
- Limit to 200 recordings
- Unlimited recording
If the number of machining operations exceeds the maximum number, the control overwrites the last machining operation.
Notes
- If you use different sizes of workpiece blanks, set process monitoring to a more tolerant setting or start the first monitoring section after pre-machining.
- If the spindle load is too low, the control may not detect any difference from idling, e.g. for a tool with a small diameter.
- If you remove and add a monitoring task again, the previous recordings remain.
Basics of operation
- You can zoom in or out of the graph horizontally by dragging or scrolling.
- If you drag or swipe with the left mouse button held down, you can move the graph.
- You can align the graph by selecting an NC block number. The control marks the selected NC block number in green within the monitoring task.