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 have been defined with MONITORING SECTION
- Reproducibility of the process 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 area
- Monitoring options column in the global area
- 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 area
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 | |
Switch on/off setup mode If setup mode is active, the control displays the settings for process monitoring. For running the program, you can switch off setup mode. | |
Open settings
Settings for the Process Monitoring workspace Settings for NC program window Available only in setup mode Available only in setup mode | |
Set the graph size to 100% | |
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 area.
The Process Monitoring workspace shows the following in the global area:
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 (for example, the number of monitoring sections) | |
Warning (for example, whether a monitoring section has been removed) | |
Error (for example, whether 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 area
If the cursor is inside a monitoring section in the NC program, the Process Monitoring workspace displays the strategy area.
The Process Monitoring workspace shows the following in the strategy area:
1 | Monitoring options icon |
2 | Switch on/off setup mode |
3 | Settings icon for the Process Monitoring workspace |
4 | |
5 | Show or hide warning and error limits |
6 | Monitoring tasks |
7 |
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 Available only in setup mode |
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
- 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 predefined percentage and static deviation.
Monitoring task MinMaxTolerance
With StandardDeviation, the control monitors whether the current machining operation is within the range of the selected references, including static expansion and a multiple of the standard deviation 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.
In each monitoring task, the control shows the current processing and the selected references as a graph. The time axis is specified in seconds, or in minutes for longer monitoring sections.
Monitoring task settings
You can change the settings of the monitoring tasks for each monitoring section. When you select the settings of a monitoring task, the control displays two areas. In the area on the left, the settings that were active at the time of the selected recording are grayed out. In the area on the right, the current monitoring task settings are shown. The Apply button allows you to save the settings from the area on the left or right. You can also remove a monitoring task from a monitoring section or add one using the plus sign.
The default values of the monitoring tasks are recommended initial values. These initial values can be adjusted for your machining purposes.
If you change the settings of a monitoring task or add a new monitoring task, the changes are identified by the * character preceding the name.
Monitoring task MinMaxTolerance
With MinMaxTolerance, the control monitors whether the current machining operation is within the range of the selected references, including the predefined percentage and static deviation.
- 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 static 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 period of time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control will trigger the responses defined for the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Trigger warning
- Trigger NC stop
- Abort program run
- Lock the tool
If the signal exceeds the limits for more than the defined hold time, the control shows a warning in the message menu.
Message menu on the information bar
If the signal exceeds the limits for more than the defined hold time, the control stops the NC program. You can then check the machining status. If you find that there is no serious error, you can resume the NC program.
If the signal exceeds the limits for more than the defined hold time, the control aborts the NC program. In this case, the NC program cannot be resumed.
If the signal exceeds the warning limits for more than the defined hold time, the control locks the tool in 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 static expansion and a multiple of the standard deviation 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 references. The references should include one optimal, one good and one only just 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 period of time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control will trigger the responses defined for the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Trigger warning
- Trigger NC stop
- Abort program run
- Lock the tool
If the signal exceeds the limits for more than the defined hold time, the control shows a warning in the message menu.
Message menu on the information bar
If the signal exceeds the limits for more than the defined hold time, the control stops the NC program. You can then check the machining status. If you find that there is no serious error, you can resume the NC program.
If the signal exceeds the limits for more than the defined hold time, the control aborts the NC program. In this case, the NC program cannot be resumed.
If the signal exceeds the warning limits for more than the defined hold time, the control locks the tool in 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 period of time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control will trigger the responses defined for the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Trigger warning
- Trigger NC stop
If the signal exceeds the limits for more than the defined hold time, the control shows a warning in the message menu.
Message menu on the information bar
If the signal exceeds the limits for more than the defined hold time, the control stops the NC program. You can then check the machining status. If you find that there is no serious error, you can resume 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 period of time in milliseconds for which the signal is permitted to be outside the defined deviation. Once this period has expired, the control will trigger the responses defined for the monitoring task.
- You can activate or deactivate the following responses for this monitoring task:
- Trigger warning
- Trigger NC stop
If the signal exceeds the limits for more than the defined hold time, the control shows a warning in the message menu.
Message menu on the information bar
If the signal exceeds the limits for more than the defined hold time, the control stops the NC program. You can then check the machining status. If you find that there is no serious error, you can resume 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 last selected references will be displayed as recordings. |
Preview [s] | The control can run selected references as a preview during program execution. The control then 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 | Toggle 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 Settings for NC program window Available only in setup mode |
4 | Checkbox for activating or deactivating the responses of all monitoring sections in the NC program Available only in setup mode |
- Depending on the cursor position in the NC program, the control provides the following areas:
- Monitoring options column in the global area
- 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 area
You can define settings and select references that apply to the currently selected monitoring section.
Monitoring options column in the global area
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. Available only in setup mode |
3 | 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) Available only in setup mode |
4 | Table with the recordings of the monitoring section The recordings refer only to the monitoring section in which the cursor is currently located. |
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. When you select a recording, the control color-highlights the references selected for this recording in this column. |
Date | The control displays the date and time of the program start or the starting time of the monitoring section of each recorded machining operation. If you select the Date column, the control sorts the table by date. |
The control displays a color representation of the coverage of each monitoring task. The coverage indicates the percentage to which the graph of the recording corresponds to the reference graph. Warning and error limits are displayed in color. When you select a row in this column, the control displays the coverage as a percentage. If setup mode is active, the control displays the coverage as a pie chart. If the coverage is at about 80%, the machining operation is still OK. In case of lower values, make sure to check the machining process.
If the potentiometer position of the feed-rate override deviates from the reference machining operation, the coverage becomes worse. If the path of the tool center point (TCP) deviates from the reference machining operation, the coverage becomes worse. In this column, the control displays notes on the responses defined for the monitoring tasks. When you select a table cell that contains a note, the control displays detailed information on the response. | |
Version | If you defined custom process-monitoring settings, the control displays a different version in this column.
The control displays letters for the different versions within the monitoring section. The control displays numbers for the different versions within at least one monitoring section. Available only in setup mode |
Delete | If you select the trash bin icon, the control deletes the table row and the associated recorded process data.
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
- Selection menu that displays the type and number of recorded machining operations
- Standard recording
- Limit recordings
- Only meta-information
- Each nth recording
The control records all information.
The control records all machining operations up to a certain count.
If the number of machining operations exceeds the maximum number, the control overwrites the last machining operation.
Input: 2...999999999
The control does not record any process data, but only meta-information, such as the date and time. This means that you cannot use this recording as a reference. This setting can be used for monitoring and logging once process monitoring has been set up completely. This setting significantly reduces the amount of data.
The control does not record process data for each machining operation. You can define after which number of machining operations the control records process data. For the other machining operations, only meta-information will be recorded.
Input: 2...20
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.
- The machine manufacturer can define the behavior of the control in connection with pallet machining in case a program is aborted (e.g., continue machining the workpieces on the next pallet).
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.
- If you double-tap or double-click a position within the graph, the control selects the corresponding NC block in the program.