Cycle
Cycle Start, Cycle End, finished-part pulses, and part counting.
IntegraIQ CNC Gateway
CNC machine-state monitoring. Without controller modification.
IntegraIQ CNC Gateway collects production-state information from legacy and modern CNC machines without changing the machine controller. The focus is not only data extraction, but also real-time machine-state monitoring, cycle tracking, part counting, and event logging.
- Passive, safe approach
- Fast retrofit deployment
- Works on older machines too
GPIO-first
production visibility built from machine-state signals
Cycle + State
cycle time, run, stop, alarm, and door state in one place
RS232 / Ethernet / USB
optional data connectivity where the machine supports it
Core concept
For CNC, the emphasis shifts: machine-state + cycle monitoring + signal capture
In injection molding retrofit projects, USB or RS232 data extraction is often the primary channel. In CNC environments, safe and quick access is often available through physical machine-state signals instead. That is why IntegraIQ CNC Gateway starts with event-based production logging built from signals.
This allows the system to measure run / stop / alarm / door open states, cycle times, part count, and downtime, while still remaining open to optional data-port integrations later.
Why GPIO?
On legacy CNC machines, physical signals often tell more than a missing data port
State
Machine Running, Spindle Running, Door Open, Alarm, Emergency Stop.
Expandability
RS232, RS485/Modbus, Ethernet, MQTT, OPC UA client, or USB data capture optionally.
Hardware foundation
A platform suited for industrial signal collection
The concept can be based on BeagleBone Black or BeagleBone Green thanks to abundant GPIO, stable Linux, Ethernet, and real-time PRU cores. For CNC use cases, the PRU is especially valuable for precise pulse counting and timing.
- opto-isolated digital inputs
- 12/24 V industrial signal handling
- galvanic isolation
- surge protection and noise filtering
- screw terminals
- separate ground strategy and fuse / TVS protection
Example I/O mapping
First prototype: 8-input passive monitoring system
- IN1 – Cycle Start
- IN2 – Cycle End
- IN3 – Machine Running
- IN4 – Alarm
- IN5 – Door Open
- IN6 – Part Counter
- IN7 – Spindle Running
- IN8 – Emergency Stop
Outputs too?
Yes, but carefully. In the base version, monitoring comes first. Optionally a status LED, relay, or "data capture active" output can be added, but the first product version should remain passive and safe.
Software logic
Physical signals become events, events become production logs
When the Cycle Start signal becomes active, the system records a cycle start with timestamp. On Cycle End or Part Counter pulse, it closes the cycle, calculates cycle time, increments part count, and archives the record.
- machine identifier
- date / time
- cycle start and end
- cycle time and downtime
- part count
- fault / alarm state
- door opening count
- shift / operator optionally
Web interface
From a local dashboard to centralized production visibility
- machine list
- current state: run / stop / alarm
- current and average cycle time
- daily part count and downtime
- event log
- CSV / Excel / PDF export
Beyond the local page, the central model is straightforward: CNC Gateway → HTTPS / MQTT / VPN → central server. This creates a product family that covers two major industrial data-source types: data-port machines and signal-port machines.
Basic
- 8 opto-isolated digital inputs
- Ethernet
- local web interface
- part count + cycle time + state log
Pro
- 16 digital inputs
- 4 outputs
- RS232 / RS485
- central server sync
- shift log + basic OEE metrics
Industrial
- 32 inputs
- isolated power
- DIN-rail enclosure
- MQTT / API
- multi-machine dashboard + remote update
Next step
Request a CNC demo or on-site assessment
If you want to see how to collect useful production-state data from CNC machines without controller modification, get in touch.