Configurable monitoring of machine tools status in smart factories

Factory management often asks for full-cross analyses of data of several machines, including data extracted from the Numerical Controls (NCs) of different brands. Unfortunately, these machines typically include proprietary software solutions for data handling, which are tightly coupled with the embedded NCs. As a consequence, the portability of a specific solution, as well as its interoperability with applications of other brands, is strongly limited. In order to overcome such limitations, we have developed an open source digital platform for the real-time monitoring of NCs data, working in collaboration with a European NC producer. The platform is independent from the control software of a specific NC machine, and is resilient against possible data loss due to temporary network downtime. Also, it is equipped with a user-friendly Web-based front-end and is highly configurable; namely, admin users can easily set the monitoring targets: errors, warnings, motor speeds, status of guards (open/close) for maintenance and safety monitoring, and so on. We conducted a preliminary case study, and the platform was able to report a misuse of a machine caused by a removal of its guards. In particular, every NC warning of that “remote station” was stored, and the user could easily visualize these warnings. This article provides an overall description of the digital platform, focusing on how data integrity and safety integrity of machines are preserved.