Wireless system ‘revolutionises’ monitoring of moving machinery
6 October 2025 
The Swiss measurement specialist Kistler has announced a system that provides wear-free, wireless transmission of signals to monitor processes and equipment in dynamic structures such as machine tools. The Telemetric Measurement System (TMS) system delivers data reliably without needing sliprings, batteries or cables. Kistler says it opens up entirely new possibilities for process monitoring in series production.
Traditional hard-wired measurement systems reach their limits when machine parts are moving or difficult to access. It is not wear and tear, but the risk of cable breakage that poses the greatest challenges – especially for components subject to dynamic loads. In addition, cables can disrupt operation and restrict the flexibility and movement of sensor systems. Coolants, chips and dust can cause connectors to malfunction. If batteries are used, they need regular maintenance and/or replacement. As a result, critical processes often go unmonitored, posing risks of wear, wastage and process instability.
Kistler’s TMS transmits signals wirelessly, accurately and continuously. It was developed primarily for use with single-channel piezoelectric measurement devices in moving machines such as turret lathes, multi-spindle machines, robots and assembly lines. Compared to indirect methods, such as spindle current analysis, the TMS – in combination with piezoelectric sensors – offers much higher sensitivities. Even tiny forces in the range of a few newtons can be detected directly, “for the first time” according to Kistler.
The system is claimed to deliver consistent measurement data in demanding locations such as machine rooms or industrial facilities, making it a cost-effective, reliable alternative where conventional technologies fail.
“Existing wireless solutions are primarily designed for R&D environments,” explains Kevin Meier, Kistler’s product manager for cooperation solutions in advanced manufacturing. “They only have a limited measuring capability and rely on specially configured systems. They are often too large or specially designed, making permanent integration into 24/7 production equipment only possible to a limited extent.”
The system consists of a mobile charge amplifier (left) and a stationary base station (right)Kistler’s Telemetric Measurement System consists of two modules that are mechanically and electrically matched. One is a miniature, single-channel charge amplifier that is mounted directly onto moving machine elements, such as tool turrets. It converts a sensor’s piezoelectric signal into a voltage and transmits it wirelessly to a base station mounted on the machine, which powers the amplifier inductively. The base receives measurement data via a near-field interface, providing a stable connection even when complex movements are involved. The gap between the modules is 1mm (±0.5).
The signals are processed with a resolution from ±48 to ±140,000pC (picoCoulombs) at an analogue voltage output of ±10V. Alternatively, digital data can be output via Ethernet at a sampling rate of up to 25 kilosamples/s, via a Web UI. Ethernet interfaces allow integration into control systems or higher-level monitoring platforms. Tool wear (in metal cutting, for example), material deviations, or irregularities in chip formation, can be detected in real time.
Following an initial set-up and coupling via the near-field interface, the base station identifies the sensor automatically and reads all relevant parameters, including calibration data, measuring range, and sensitivity within milliseconds. The system is immediately ready for measurement – without manual intervention or waiting times. Installation is said to be fast, precise and reproducible, thanks to defined coupling points.
The contactless, high-frequency signal transmission is bidirectional and resists interference, even under harsh conditions. The measurement system also resists chips, coolants, and vibrations because of its closed aluminium die-cast housing and ceramic-reinforced transmission surfaces.
Kistler: LinkedIn
