4dot Mechatronic Systems will introduce its new machining tool and process monitoring system at the 2026 International Industrial Fair in Brno. The system monitors machining processes directly during production and can react to process changes in less than 1 ms, with detection of monitored conditions completed within 200 µs.
Depending on the application, the system uses vibration sensors, strain sensors, or a combination of both. It can detect tool-workpiece contact, tool wear, tool damage or breakage, and collision events. The same hardware and sensor platform can be used not only for process monitoring, but also for machine condition monitoring and technical diagnostics.
For users, this means earlier detection of emerging problems and a reduced risk of collisions, machine failures, and damage to machines or spindles. At the same time, the system can help reduce scrap, make better use of cutting tool life, and improve production stability. Another important benefit is the automation of routine and repetitive operator tasks. Continuous process supervision can be partly automated, creating a foundation for more autonomous machine operation.
The solution also provides remote access for system configuration, management, and technical support. This makes it possible to adjust and support the system remotely, reducing the need for on-site service visits and simplifying long-term operation at customer sites.
The technology has been validated both under laboratory conditions and in real industrial production. The development process combined laboratory testing with gradual validation of system functions directly on production machines at industrial partners.
The technical solution is protected, among others, by patents CZ 308664 “Diagnostic System for Machine Tools” and CZ 308886 “Strain Sensor and Strain Measurement Assembly Comprising the Sensor”. The patent protection is complemented by 4dot’s proprietary know-how in signal processing and industrial implementation.
The monitoring unit was developed within project FW07010019 “Research and Development of Shared Services for Machine Tool Monitoring Using 5G Networks”, supported by the TREND Programme of the Technology Agency of the Czech Republic, in cooperation with Brno University of Technology and industrial partners.
The new 4dot system will be presented at the 2026 International Industrial Fair in Brno, Pavilion F, Stand 227.