PrepMaster Analytics: Smart Tool Condition Monitoring
Continuously monitor critical machine components using intelligent sensors, process data, vibration analysis, and AI-powered image recognition.
Quick access to errors and warning messages for all components of an automated system
Automatic saving of video sequences for effective error analysis
Automatic video monitoring of processes in the machine
Assignment of service tasks for the components of an automated system
Clear display of maintenance tasks in the calendar
Clear display of maintenance tasks in the calendar
Automatic evaluation of maintenance efficiency
Automatic evaluation of maintenance work and costs
Simple identification and selection of spare parts for an automated system
All advantages at a glance
SmartSense TCM – Insert Monitor (Option)
The SmartSense TCM – Insert Monitor provides intelligent tool condition monitoring for the cutting inserts of the HERZOG HS-F 1000 milling machine. By continuously analyzing process signals such as torque and vibration, the module detects characteristic wear patterns, abnormal machining conditions, and end-of-life criteria for individual inserts. Configurable warning limits and automated notifications support predictive maintenance, maximize tool utilization, and ensure consistently high sample preparation quality for OES analysis.
SmartVision TCM – Insert Monitor (Option)
The SmartVision TCM – Insert Monitor combines advanced machine vision with artificial intelligence to automatically evaluate the condition of milling inserts. High-resolution images are analyzed using deep-learning algorithms to detect wear, chipping, and cutting-edge damage under real industrial operating conditions. Continuous monitoring of insert condition enables objective wear assessment, optimized tool replacement, reduced tooling costs, and consistently high milling quality while minimizing manual inspection effort.
SmartSense TCM – Disc Mill Monitor (Option)
The SmartSense TCM – Disc Mill Monitor continuously analyzes the grinding process of HERZOG vibrating disc mills by recording grinding power, energy consumption, and characteristic process parameters. Intelligent process evaluation identifies grinding phases, material agglomeration, and the influence of grinding aids, providing valuable insights into material behavior and grinding efficiency. The module supports optimization of sample preparation, improves analytical reproducibility, and enables rapid determination of material grindability for both laboratory and production applications.
SmartSense TCM – Disc Mill Monitor Plus (Option)
The SmartSense TCM – Disc Mill Monitor Plus extends the standard Disc Mill Monitor by integrating high-resolution vibration analysis for advanced machine condition monitoring. In addition to process performance, the module continuously evaluates the mechanical condition of the grinding system, detecting wear of grinding vessels, grinding elements, and swing aggregate components at an early stage. This enables condition-based maintenance strategies, reduces unplanned downtime, and increases the reliability and availability of critical sample preparation equipment.
SmartSense TCM – Pneumatic Cylinder Monitor (Option)
The SmartSense TCM – Pneumatic Cylinder Monitor continuously monitors the condition of critical pneumatic cylinders installed throughout the laboratory automation system. By evaluating stroke times, cycle times, and statistical process trends using SPC methods, the module detects wear, air leakage, contamination, and mechanical degradation long before functional failures occur. Automated alarms and trend analyses support predictive maintenance strategies, helping to maximize equipment availability while reducing maintenance costs and unplanned downtime.