Teach it once. Trust it forever.
What is Power Monitoring?
Power Monitoring detects deviations – before they become a problem
In modern manufacturing, every second counts. A broken tool, declining process quality, or unplanned machine downtime can be costly. Power Monitoring by Schubert System Elektronik helps prevent exactly that.
The system measures the active power of a drive and records its power curve in relation to the manufacturing process. A reference curve is taught once and continuously compared with the current actual curve.
If the process deviates – whether due to a blunt, missing, or broken tool – the system immediately triggers an alarm or stops the machine automatically.
The system automatically detects:
- Tool breakage
- Blunt tools
- Missing tools
- Process deviations
- Load peaks
Whether for process optimization, tool control, or quality monitoring: Schubert Power Monitoring creates transparency over the actual process flow.
How the system works
Learn once. Monitor continuously.
On first tool use, the system creates a teach curve with the typical power data. This serves as the reference for continuous monitoring of the machining process.
Deviations such as tool wear, tool breakage, or a missing tool are detected immediately. The system reports the fault to the machine controller and stops the process before damage or scrap occurs.
Software / Live Mode
🟢 Normal process
🔴 Tool wear → increasing power demand
🔴 Tool breakage → characteristic peak
🔴 Tool missing → power drop
In the event of a fault, the system immediately reports a fault to the machine controller and stops the process before damage or scrap occurs.
DPU or Gateway Solution?
System solutions for different requirements
From a compact, autonomous system for individual drives to a centralized solution for machines with many monitored drives: Schubert Power Monitoring can be flexibly adapted to the application, system size, and existing infrastructure.
DPU Solution
Data Process Unit
Compact and autonomous for 1–2 drives
The DPU Solution captures and processes the process data directly in the Data Processing Unit. Deviations such as tool breakage, tool wear, or missing tools are reliably detected.
An external PC is not required during operation. It is only needed for configuration and data readout.
Gateway Solution
Data Gateway & External Process Unit
Powerful for monitoring multiple drives
The Gateway Solution consolidates the process data of multiple drives and transfers it to a PC for processing. The data is evaluated there and deviations such as tool breakage, tool wear, or missing tools are detected.
A PC is permanently required for operation.
DPU Solution
Gateway Solution
Number of drives
1–2
Multiple
Data processing
Directly in the DPU
On a PC
PC during operation
Not required
Required
System architecture
Compact & autonomous
Centralized & scalable
PC required for
Configuration & data readout
Operation, processing & configuration
DPU Solution | Gateway Solution | |
| Number of drives | 1–2 | Multiple |
| Data processing | Directly in the DPU | On a PC |
| PC during operation | Not required | Required |
| System architecture | Compact & autonomous | Centralized & scalable |
| PC required for | Configuration & data readout | Operation, processing & configuration |
Your benefits at a glance
Process reliability
Deviations are detected and reported at an early stage.
Less scrap
Identify faulty processes before more parts are produced.
Automated monitoring
Monitor processes continuously and reliably – without manual inspection.
Flexible integration
DPU or Gateway – the right solution for your application and system architecture.
Typical application areas
For numerous machining applications in industrial manufacturing.
Contact
Would you like to know if Power Monitoring is suitable for your application?
Our experts will support you in selecting and integrating the right solution.