Unfavorable chip shapes and chip pockets in critical areas can quickly jeopardize your entire CNC process. Rotoclear’s new ChipDetect AI identifies chip shapes and chip pockets in real time, categorizes them by risk level, and allows you to track their development at any time via the Rotoclear C Pro timeline.
Critical conditions are automatically detected by the AI. The causes can be analyzed in detail in retrospect — and then resolved in a sustainable manner.
The New AI Module for the Rotoclear C Pro
ChipDetect AI is a new AI feature available exclusively on the Rotoclear C Pro.
Chips are critical to the process! Why chip analysis is so important.
Long, irregular chip shapes, chip pockets, or chip buildup in the cutting zone can compromise the tool, workpiece, surface finish, and process reliability.
At the same time, it is almost impossible to continuously monitor chip formation during the CNC process — let alone document it!
If you understand chip formation, you can optimize processes.
Those who can analyze and evaluate chip formation can identify the causes of key process risks—and subsequently eliminate them! Optimizing chip formation by adjusting process parameters can
- Reduce scrap costs and waste,
- Minimize downtime and
- improve product quality.
In other words: Analyzing chip formation provides the essential data needed to increase your productivity.
The Rotoclear ChipDetect AI – automated tracking of your chip formation!
ChipDetect AI is a new AI module for the Rotoclear C Pro. The AI analyzes camera images from inside the machine in real time, identifies chip classes and chip-related conditions directly in the live image, and continuously records which types of chips were produced during the CNC machining process.
ChipRisk
The ChipRisk status shows process managers the current risk of critical chip buildup or chip jams in the live view, allowing them to quickly assess the current process situation.
ChipReview
The ChipReview graph in the Rotoclear C Pro timeline allows for post-processing analysis of chip formation. ChipReview visualizes the development of the different chip types throughout the entire machining process.
What does ChipDetect AI offer? An overview of the top 5 benefits.
With ChipDetect AI, chip formation transforms from a difficult-to-control side process of CNC machining into a continuously analyzed process signal. This brings a whole range of important benefits.
A chip jam in the cutting zone or a chip pocket near the tool can pose a risk to tools, workpieces, or machine components. ChipDetect AI automatically identifies critical developments in the live image — and provides process managers with a risk assessment at a glance via the ChipRisk status. This enables users to take action during pre-production before unfavorable chip formation leads to costly damage in series production.
Every unplanned interruption costs productive time and results in costly downtime. Continuous monitoring of chip formation is essential for making timely adjustments to machining parameters — and can thus significantly reduce manual interventions and downtime.
Unfavorable chip formation can scratch surfaces and even compromise the dimensional accuracy of a workpiece. If unfavorable chip shapes and critical chip pockets are detected early, processes can be adjusted before defective parts are produced. This can significantly improve the quality of the workpieces.
The ChipRisk Status condenses the current state of chip formation into easy-to-understand risk information. This allows operators to see at a glance which machine currently requires attention — enabling them to monitor multiple machines simultaneously or even check the current risk status remotely.
ChipDetect AI continuously tracks and records chip formation. Using the ChipReview Graph in the Rotoclear C Pro timeline, you can analyze the process retrospectively at any time — and identify the causes of critical chip classes and chip pockets. This allows you to continuously optimize your chip formation.
What can ChipDetect AI do?
Real-Time Chip Detection During Machining Processes
ChipDetect AI continuously analyzes all chips visible in the camera image. It detects and classifies different chip shapes and chip-related conditions. This allows operators to immediately see which chip shapes are present and whether a critical situation is developing.
Automatic Classification of Chip Shapes
The AI classifies detected chips into predefined chip shape categories. These include, among others, large, irregular chip shapes such as tangled chips or ribbon chips, as well as medium and small chip shapes, which may indicate more stable process conditions. This makes it possible to clearly evaluate chip formation.
Detection of Critical Chip Pockets and Chip Jams
Chip buildup is particularly critical, as it can directly or indirectly jeopardize the process. ChipDetect AI helps detect critical chip pockets near workpieces or tools at an early stage.
At a Glance: Clear Chip Status in the Live View!
The ChipRisk Status consolidates conditions detected in the live view into an immediately understandable risk assessment. This allows you to check in a flash whether a critical chip buildup is forming or whether the process is stable. For easy monitoring and even greater safety during operation.
Automatic Tags in the Rotoclear C Pro Timeline
The Rotoclear C Pro can automatically mark critical chip-related events on the timeline. For example, if a defined chip shape, a chip nest, or a chip jam is detected, the system automatically places a marker at the corresponding point. This allows you to immediately jump to the key moments when reviewing the data and analyze the causes in detail.
Analyze the distribution of chip types on the timeline
Our ChipReview graph in the Rotoclear C Pro timeline shows how the different chip shape categories evolve over time. The continuous line graph helps analyze machining processes and make changes in chip formation easier to understand. This is particularly valuable for process optimization, quality management, and continuous improvement.
Designed for the Rotoclear C Pro!
ChipDetect AI works exclusively with the Rotoclear C Pro — the monitoring system with the Visual Backup feature. The AI tool uses high-resolution images of the machine’s interior as the basis for analysis, categorization, and evaluation.
ChipDetect AI thus adds a new dimension to the Rotoclear C Pro: the automatic detection, assessment, and evaluation of chip-related process conditions.
Who would find ChipDetect AI particularly interesting?
- Machine operators can see the current risk status at a glance and don’t have to constantly monitor chip formation themselves.
- Production managers receive new data and analyses to optimize process stability and quality.
- Machine OEMs gain additional AI-powered process intelligence and can offer their customers new options for process monitoring and quality assurance.
Tailor chip detection to your process!
Every machining process is different: the machine, material, tool, camera angle, cooling, and chip formation all shape the unique camera image. With the subscription model, you can therefore train ChipDetect AI specifically using images from your machine — and thus tailor it precisely to your specific process conditions!
Greater precision through personalized AI training
With the subscription model, you can upload selected recordings from your processes to our AI Tuning Hub. We use this data to train and fine-tune ChipDetect AI specifically for your applications. This can significantly improve detection performance for your specific machine, material, and process conditions.
The ChipDetect AI subscription model includes four custom training sessions per year.
Four simple steps to process-optimized ChipDetect AI
Upload video data
Upload selected recordings from your machine to the AI Tuning Hub.
Train ChipDetect AI
We train and fine-tune ChipDetect AI based on your images and process conditions.
Get a custom-optimized version
Within a few days, you'll receive a new version of ChipDetect AI that has been precisely tailored to your processes.
Download and install
Download the new version from the AI Tuning Hub and install it on your control unit—that's it.
Your data is always protected.
Your data remains within a closed data cycle throughout the entire training process. It is used exclusively for the agreed-upon AI training, is not shared with third parties, and is deleted upon completion of the training.
Experience ChipDetect AI Live
Curious? Sign up for a free demo to see how ChipDetect AI detects and highlights chip shapes, chip pockets, and critical process conditions, and makes them available for analysis in the Rotoclear C Pro timeline.
The foundation of ChipDetect AI
With the Rotoclear C Pro, you can seamlessly monitor the machining processes inside your machine tool from multiple perspectives.
