ZerspanungsCopilot · AI process monitoring for machining
Hear what's happening in the process. Know what to do.
We help companies monitor and optimise machining processes with AI-powered sensor technology. The ZerspanungsCopilot listens to the process, detects deviations early and gives your machine operators targeted support.
Starting point
With complex workpieces, experience makes the difference
Quality and uptime often depend on the intuition of experienced operators. Signs of wear, chatter or material defects emerge during the process, but even with today’s technologies they are often difficult to detect in real time. This makes continuous improvement and predictable production more challenging.
When defects are only discovered in the finished part, avoidable costs arise from scrap, rework, quality issues and machine downtime.
Recommendations for action through intelligent monitoring
Answers instead of alarms
The ZerspanungsCopilot doesn't just report that something is wrong. It tells your team what makes sense now: as an overview, as a report or in a dialogue directly at the machine.
How it works
Three technologies. One copilot.
How measurements become a recommendation: process monitoring in machining that genuinely helps your team.
01
AI-powered acoustic emission (AE) sensor: listens to the machine
It measures the finest vibrations generated during machining. An AI detects patterns, for example of wear, chatter or material defects, directly in the process.
02
Data engineering: brings everything together
Sensor, machine, process and production data come together in one place, live and continuously over time.
03
Machine learning: understands the data
The models learn what is normal. From this, the AI recognises patterns and deviations, allowing you to understand the process in unprecedented depth and see where optimisation is possible.
04
Dashboard and chatbot: interact with your employees
Depending on your preference, your team receives the results as an overview, a report or a message, for example via a machine-specific chatbot.
Definition: AE sensor stands for acoustic emission sensor. Our in-house sensor measures in the ultrasonic range and is built for industrial use. Equipped with specialised AI, it efficiently monitors even the most complex production scenarios.
Your advantage
What the ZerspanungsCopilot delivers
Listens to the machine
Our in-house developed, AI-powered acoustic emission sensor detects what machine data alone cannot show.
Live in the process
Machine, tool or workpiece: condition monitoring at a new level.
Condition monitoring & process optimisation
A concrete recommendation instead of a mere warning. Your team knows what to do next.
Modular expansion stages, tailored to your requirements
Existing partial solutions remain in place. We add exactly what delivers the greatest value.
Your benefits
Greater process reliability in every machining operation
Increase efficiency
Less downtime and rework, because deviations are spotted early.
Reduce scrap
Problems are detected during the process, not on the finished part.
Ensure quality directly
Your team responds to concrete recommendations while the workpiece is still in the machine.
Optimise tool life
Tools are changed when wear requires it, rather than at fixed intervals.
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Proprietary sensor technology
Sensor technology and AI from a single source
The technology behind our AE sensor emerged from many years of research into material monitoring, combined with ML algorithms and a deep understanding of physical processes. Today, our sensor technology is used in some of the most complex manufacturing processes in industry.
Implementation
Your ZerspanungsCopilot in 4 steps
We support you from the initial analysis through to ongoing operation: structured, transparent and practical. Consulting and implementation from a single source.
Together, we capture the conditions and constraints of your machines, processes and IT. We clarify which data is already available and where the biggest levers are.
Based on the analysis, we define which expansion stages make sense and how they fit into your existing environment, so you always know which steps are planned.
Our experts implement the right solution, retrofit the AE sensor if required and seamlessly integrate the dashboard or chatbot into everyday work at the machine.
After roll-out, we can monitor performance and optimise the ZerspanungsCopilot on request.
FAQ
Frequently asked questions about the ZerspanungsCopilot
For machining equipment, for example CNC machining centres. In the analysis phase, we jointly clarify which data your machines already provide and how we connect them.
No, but we recommend it. Even the basic stage consolidates and analyses the data your machine provides. The AE sensor adds what machine data alone cannot show. It can also be retrofitted later.
They remain in place. We add exactly what delivers the greatest value.
The finest vibrations generated during machining. An AI detects wear, chatter, material defects or other anomalies in them.
As an overview in the dashboard, as a report or in a dialogue with the chatbot directly at the machine. Together, we decide which format best fits your daily work.
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