Collecting and using production data from machine tools has become a key challenge for today’s machining workshops. Improving efficiency, reducing downtime, and enabling real-time production monitoring are just some of the benefits made possible through machine tool connectivity.
But how do you actually connect a CNC machine tool? What are the available technical approaches? And what costs and constraints should manufacturers anticipate?
1. Two Main Approaches to Machine Tool Connectivity
1.1 Connectivity via I/O Signals
A historical and widely used method.
Additional hardware modules are installed on electrical signals or serial ports.
Advantages: universal solution, compatible with almost any machine.
Limitations: very limited data (machine running or not, piece counts), no detailed status information.
1.2 Direct Connectivity to the CNC (Control)
Uses protocols provided by the machine tool or CNC manufacturer (Fanuc, Heidenhain, Siemens, Mazak, Okuma, etc.).
Advantages: much richer data (programs, detailed statuses, alarms, cycle times…), no additional hardware needed.
Limitations: strong dependency on the machine model and manufacturer protocols, with multiple cases to handle.
2. Protocols for CNC Connectivity
Proprietary libraries
Access through SDKs offered by the manufacturer.
Sometimes free (e.g., certain D.Electron models), sometimes subject to paid licenses (Fanuc, Heidenhain).
Open standards
OPC UA: particularly widespread in Europe, driven by Siemens.
MTConnect : more developed in the U.S., used by Mazak, Okuma.
File ou Network-Based Exchanges
Some machines (e.g., Röders) export production data in files, while others rely on TCP or UDP network connections to share their data (e.g., Brother).
Complementary approaches (CNC + PLC)
Combining CNC data with PLC signals makes it possible to broaden the range of collected information.
3. The Cost of Machine Tool Connectivity
💡 A point often underestimated by manufacturers
On the machine side: some CNCs require activation of connectivity options, often around €900 per machine (Heidenhain 640, Siemens Sinumerik, Mazak).
On the software side: some manufacturers require an additional SDK license for access to their proprietary libraries (Fanuc, Heidenhain), impacting overall solution costs.
Free options: some manufacturers provide connectivity protocols at no extra charge.
4. Why Prioritize CNC Connectivity for Data Acquisition?
Direct access to richer and more accurate data.
No external hardware required.
Higher precision and reliability in data collection.
At Atsora Solutions, we clearly favor this second approach, as it enables us to power our machine tool monitoring and production control applications with high-value, real-time data.
Conclusion
Machine tool connectivity is now an essential step for any workshop aiming to embrace Industry 4.0.
Whether through I/O signals or directly via the CNC, each method comes with its advantages, costs, and constraints.
👉 Beyond connectivity itself, another crucial topic remains: the security of machine connections. We will explore this subject in a dedicated article.