Full Report
Kistler for the first time achieves wireless, wear-free transmission of signals for process and tool monitoring in dynamic structures such as turret lathes.
Analysis Summary
# Kistler Wireless Telemetric Measurement System for Dynamic Process Monitoring
## Key Points
- **Core Innovation:** Kistler has introduced a Telemetric Measurement System (TMS) enabling the first time wireless, wear-free transmission of signals for process and tool monitoring in dynamic structures like turret lathes.
- **Reliability without Wires/Batteries:** The system reliably transmits data without relying on traditional problematic methods such as slip rings, external batteries, or physical cables, mitigating risks like cable breakage, wear, and maintenance overhead.
- **High Sensitivity:** When combined with piezoelectric sensors, TMS offers significantly higher measurement sensitivity than indirect methods (e.g., spindle current analysis), capable of detecting forces in the few-newton range directly.
- **Intended Use:** Developed for single-channel piezoelectric measurements in moving machine elements (turret lathes, multi-spindle machines, robots, assembly lines) in serial production environments (automotive, aerospace, medical technology).
## Threat Actors
- **Not Applicable:** This report describes a technological advancement/product launch by Kistler, not a cyber threat, adversary, or security incident involving malicious actors.
## TTPs
- **Not Applicable:** This report details engineering techniques for data transmission, not adversary Tactics, Techniques, and Procedures (TTPs).
- **Techniques Described:** Wireless near-field transmission, inductive power supply, high-resolution analog/digital data output (Ethernet up to 25 kSps).
## Affected Systems
- **System Components:** Charge Amplifier Unit type 5190A (mounted on moving parts) and Base Unit type 5290A (machine mounted).
- **Target Environments:** Dynamic structures such as turret lathes, multi-spindle machines, robots, assembly lines, metal cutting processes, and plastics processing.
- **Physical Vulnerabilities Addressed:** Traditional hard-wired systems limited by cable breakage, disruption from coolants/chips/dust fouling connectors, and battery maintenance.
## Mitigations
- **System Implementation:** Integrating Kistler TMS to replace conventional measurement systems that are vulnerable to mechanical failure or maintenance needs in dynamic applications.
- **Data Integration:** Output data (Ethernet) enables straightforward integration into existing control systems or higher-level monitoring platforms like PTS App or maXYmos for real-time detection of tool wear or process irregularities.
- **Durability:** The system utilizes closed aluminum die-cast housing and ceramic-reinforced transmission surfaces for resistance against chips, coolants, and vibrations.
## Conclusion
The introduction of Kistler's TMS represents a significant operational improvement for industrial monitoring, offering a robust, maintenance-free wireless solution where traditional wired systems face reliability challenges due to high dynamics and harsh environments. This technology enables previously difficult-to-monitor processes to provide high-fidelity data critical for reducing scrap and ensuring process stability in continuous 24/7 manufacturing operations.