Products | 4dot

Process monitoring

Real-time monitoring of the process, quality, and tooling.

Bulk forming

Ensuring consistent output and eliminating tool crashes are key advantages of process monitoring in bulk forming. The system is applicable to both single-operation and progressive presses.

In progressive presses, monitoring is ensured even during the start-up and run-down of production, as the 4dot system works with boundary conditions. Each operation has its own set of limits, allowing for extremely narrow tolerances and maximum quality.

To monitor and control forming force, the Deformation Module is used. It tracks force progression and protects the machine from overload. The Energy Module monitors tool condition by detecting wear, tool damage, and process faults—even in the forming of small components.

Sheet metal forming

Tool protection during pressing is ensured by maintaining high precision of individual sheet forming parameters. The Energy Module enables monitoring of lubrication, smooth operation, and detection of potential tool galling.

The Deformation Module tracks both pressing force and the force during tool opening, reliably detecting changes in tool condition regardless of the pressing itself.

The Motion Module evaluates alignment and flatness of the working tool parts during operation, allowing early detection of deviations from the desired state.

High motion precision and good tool condition are essential for achieving high production quality.

Machining

Process monitoring by 4dot enables tool replacement before quality deteriorates, stops machining in case of cutting insert breakage, detects collisions, and monitors tool–workpiece contact for adaptive machining control.

The core of the technology is the Energy Module, which detects insert breakage, wear, contact with the material, and potential collisions. For force evaluation and deeper analysis of the machining process, the Deformation Module is also used.

Monitoring can be applied to both turning and rotary tool machining.

Grinding

Real-time monitoring of workpiece and tool geometry, as well as surface integrity assessment, is made possible by 4dot process monitoring, which provides information for adaptive control of the grinding process.

The system is based on the Energy Module, which continuously monitors material removal intensity during grinding. In combination with patented MUSA analyses, it allows evaluation of current workpiece geometry and abrasive condition.

When combined with tool displacement data, it is also possible to precisely monitor the amount of material removed—crucial for ensuring surface integrity in stressed components such as rolling bearings.

Technical diagnostics

Regular data collection, large data volumes, and the ability to respond immediately.

Bearings

Machine availability and scheduled maintenance interventions are the main benefits of bearing condition monitoring. Timely interventions extend the lifespan of key components, thereby increasing machine utilization and reducing maintenance costs.

Patented 4dot MUSA analyses enable condition monitoring of both slow-speed and high-speed bearings. The same analyses used for non-rotating machinery can also be applied to linear guides, ball screws, and slow-speed bearings. This means that with 4dot technology, bearing condition monitoring is not limited by rotational speed.

Monitoring is primarily performed using the Energy Module, and in some cases supplemented by the Temperature Module.

Product sheet

Non-rotating components

Continuous condition information enables effective maintenance planning and increases machine availability—even when monitoring non-rotating components.

4dot’s patented technologies expand the possibilities of predictive maintenance into areas that were previously limited by technical constraints of conventional methods.

Examples of monitored conditions in non-rotating components include:

- Ram clearance
- Condition of linear guides
- Tool deformation
- Machine anchoring
- Machine frame deformation

These are monitored using the Energy, Motion, Deformation, and Temperature Modules.

Product sheet - force

Services

Real-time engineering support — live.

RAW

The name of the RAW service is derived from the raw data package (RAW) that the unit regularly sends to 4dot servers for detailed analysis. This data is of at least the same quality as that collected by traditional walkaround diagnostic systems and is transmitted for further processing at regular intervals — typically every few minutes.

The RAW service includes:

- Continuous access to the web application (24/7)
- Automated data processing
- Remote software updates for the unit

Engineering

The Engineering service builds on RAW by adding a layer of expert engineering activities. 4dot technicians continuously optimize analysis settings based on the latest insights and the current needs of each specific machine.

Engineering support is also available in real time — data is streamed directly to 4dot servers, where it can be immediately consulted with the 4dot team by operators, process engineers, or maintenance staff.

The Engineering service includes:

- Automated analysis evaluation
- Email notifications
- Technical support in 8/5 mode (8 hours per day, 5 days per week)

Proactive

The name of the Proactive service — an extension of the Engineering service — reflects the proactive approach taken by both 4dot and the customer. The goal is to ensure maximum equipment availability.

While the Engineering service focuses, for example, on early detection of bearing damage, Proactive goes further — it targets root cause identification and proposes effective corrective actions.

The Proactive service includes:

- On-demand equipment condition checks
- Management of user visualizations accessible via the web application

Signal processing modules

Parallel signal processing and patented MUSA analyses.

Energy Module

The Energy Module uses emitted energy from the machine or production process to effectively monitor technical condition and process behavior. This energy is measured using vibration sensors (accelerometers) or strain sensors (strain gauges). With a sampling frequency ranging from tens to hundreds of kHz and simultaneous signal acquisition and processing, the module offers a wide range of applications.

Typical applications include:

- Monitoring the condition of slow-speed bearings, ball screws, and linear guides
- Process monitoring of cutting inserts during machining
- Quality control of forming operations

This module is ideal for tasks where the emitted mechanical energy is a key indicator of machine condition or process quality — whether in technical diagnostics or manufacturing process monitoring.

Video

Motion Module

The Motion Module analyzes the movement of the machine or tool. It uses absolute acceleration measurement and is not dependent on a reference point — making it reliable even in demanding environments.

When used with 4dot PM3 sensors, which allow acceleration measurement starting from 0 Hz, the signal can be accurately integrated into velocity and position, even at low speeds. Measurement is suitable for motion ranges from tenths of a millimeter to several centimeters.

Typical applications include:

- Measuring ram clearance
- Monitoring tool motion during forming
- Evaluating vibration and machine anchoring
- Checking alignment and flatness in forming operations

This module is designed for applications where machine condition or process quality is expressed through mechanical motion.

Deformation Module

The Deformation Module is used to assess deformations — changes in the shape of a machine or tool. These changes are primarily caused by mechanical loading, thermal expansion, or gradual plastic deformation.

It uses 4dot SM strain sensors, which offer high sensitivity and a wide measurement range. This makes the module suitable for a variety of applications, such as:

- Monitoring forces in heavy industry
- Monitoring loads on forming machines
- Assessing force distribution across multiple forming operations
- Monitoring cutting forces during machining
- Detecting tool galling during pressing of small components

This module is intended for use cases where machine condition or process behavior is reflected in temporary or permanent deformation of a machine or tool.

Temperature Module

The Temperature Module measures the temperature of machine or tool components. It supports a wide range of sensors, which can be adapted to various applications and operating conditions.

Temperature monitoring is critical for:

- Verifying the proper function of lubrication systems
- Monitoring thermal loads on tools
- Assessing the thermal stability of the machine structure
- Tracking process parameters
- Supplementary measurement for bearing condition monitoring

This module is used in situations where machine condition or process quality is expressed through temperature variation.

Hardware and software

Designed for production.

Vibration sensor PM3

The 4dot PM3 is a three-axis vibration sensor with a frequency range from 0 Hz up to 24 kHz. Thanks to its ability to measure low frequencies, the signal can be reliably integrated into velocity and position. The sensor’s compact dimensions are designed for installation on forming tools as well as forming and machining machines themselves. The signal is transmitted via a shielded twisted-pair cable, and the sensor operates at 20–30 V DC. With three axes, a connectorless design, and a stainless steel body, the sensor offers wide applicability with minimal space requirements.

Technical Data sheet

Price list

Strain sensor 4dot SM

The 4dot SM is a precise and robust strain sensor developed for forming, machining, and heavy industry. Its patented construction allows placement directly near tools, even in applications demanding high sensitivity. The semiconductor sensing element enables both static and dynamic process measurements. Thanks to its preloaded mechanical design, the sensor can measure dynamic effects even on corroded surfaces.

Vibration sensor PM3L

External mounting requires a robust sensor and durable wiring. The L version has been designed to operate in the most demanding applications such as in metallurgy, forming machinery and mining. A torque wrench and M8-threaded holes are sufficient for mounting.

Rarog software for touch panels

Rarog software is an extension of the monitoring unit designed for touch panel interfaces. It enables real-time data visualization and direct operator interaction at the machine. It can display values such as force or temperature, adjust process monitoring settings (e.g., for automatic machine shutdown), and allow operators to input operating states. The application can run on Windows or Linux systems, or in a web browser environment.

cRIO monitoring unit

Monitoring units based on CompactRIO hardware from National Instruments enable real-time acquisition and processing of large volumes of data. Thanks to their modular architecture, these units can be configured precisely to meet the requirements of a specific machine — supporting measurement of vibration, deformation, or temperature.

In addition, the unit can process other analog (voltage) and digital inputs. The custom software developed by 4dot ensures not only real-time data processing but also communication with 4dot servers or direct integration with the machine. Signal processing is performed using FPGA technology.