How to Start Monitoring Your CNC Machines for Free (Mazak Edition)

Monitoring CNCs means collecting machine status, cycle data, and utilization for analysis (OEE, downtime, productivity). Mazak machines can often share data via open protocols, network services, or simple file logs. This guide covers low-cost methods (MTConnect, network file polling, DIY I/O) to pull basic status and performance data from Mazak CNCs and visualize it, using free software like dashboards or simple scripts. Focus is on Mazatrol Smooth/Smart and Matrix controls (including Smooth AI, Fusion, Nexus, etc.).

Mazak Control Generations & Connectivity

Mazak CNC controls come in generations with different data interfaces. Recent Mazatrol Smooth (SmoothX/G, SmoothC/Smart, Smooth AI, Nexus, Integrex, VARIAXIS, etc.) are PC-based Windows controllers that almost always include an Ethernet port and can run MTConnect. Controls made since ~2010 are very likely to support it. Older Matrix- or Fusion-based controllers may still have Windows OS or Ethernet, but often require installing Mazak’s MTConnect adapter or a PC-based adapter. Linux-based “SMART” controllers (Mazatrol SmoothG on older machines) have no built-in data link unless you add MTConnect.

Most Mazak controls have an onboard Windows environment. You can usually bring up the Windows taskbar by entering EXPERT → POSITION → Setup → Show Windows Taskbar on a Smooth screen. Once in Windows, check the Network settings (make sure the machine has a static IP on your LAN) and look for an MTConnect program or service. Also look for signs of an Ethernet port (often inside the control cabinet) or built-in FTP/SMB sharing.

Free Monitoring Methods

1. MTConnect (preferred when available). If your Mazak supports it (most Smooth and many Matrix/Fusion do), the machine’s MTConnect adapter will publish XML data via HTTP. You can then use any free MTConnect agent or client to pull it. Tools will query the Mazak (usually on port 7878) and collect tags like machine state, axis loads, spindle RPM, etc. MTConnect-based monitoring can be near real-time (seconds of latency) and integrates well with dashboards.

2. Network file/FTP polling (for basic stats). If MTConnect is not available or not enabled, Mazak’s Windows controls still allow file sharing. You can install an FTP server on a SmoothAI or SmoothX/G control. Then CNC programs or a user can save status logs, part-count files or error logs to that shared folder. On a PC, a simple script (PowerShell, Python with watchdog, etc.) can monitor that folder for changes, read the latest file, and extract data. This approach is batch polling and not truly real-time, but it works on any networked Mazak.

3. OPC UA or I/O tapping. Mazak offers an OPC UA Server option (a software add-on) for some machines, but it’s typically paid. For older controllers without network, some shops wire digital outputs into a microcontroller to log run/stop signals.

Checking Your Machine’s Capabilities

To begin, power on the CNC and access the Windows desktop through the EXPERT button, then POSITION mode, and select Setup followed by Show Windows Taskbar. From the Windows environment, open the Network settings and confirm the machine has a static IP address assigned. Use a terminal on your PC to run telnet <machine-ip> 7878 and verify the MTConnect adapter is active and listening.

Once connectivity is confirmed, assign a static IP to the controller by going to Network and Sharing Center → Change adapter settings. Right-click on the Ethernet interface, open Properties, select IPv4, and manually enter an address (such as 192.168.1.100), subnet mask (255.255.255.0), and leave the gateway blank.

Next, locate and start the MTConnect adapter on the CNC. If configuration options are available, enter the machine name, adjust the sample rate if needed, and ensure the adapter is enabled. A restart of the CNC might be required to apply these settings.

On a separate PC or server, install a compatible MTConnect data collection agent. Configure it to poll the CNC using the endpoint http://<CNC-IP>:7878/current. To confirm the data feed is working, you can use a simple Python script:

import requests
r = requests.get("http://192.168.1.100:7878/current")
print(r.text)

To extract and use the data, parse the XML feed using an XML library. Here's an example using Python:

import xml.etree.ElementTree as ET
root = ET.fromstring(r.text)
for elem in root.iter():
    print(elem.tag, elem.text)

After parsing, the data should be formatted into a time-series format and written to a storage system. You can use CSV, SQLite, or InfluxDB, depending on your preference. A formatted CSV row might look like this:

timestamp,machine,execution,spindle_speed
2025-12-23T12:00:00Z,Mazak-1,ACTIVE,1500

With the data collected and stored, connect a visualization tool to your data source and build dashboards. Create panels that show current machine status, spindle speed over time, cycle counts, and downtime trends.

Before deploying fully, simulate production cycles on the machine to validate that all expected states and transitions are logged correctly. Monitor the flow for data loss, irregular update rates, or disconnects.

Alternate Method: File/Share Monitoring

1. Enable Windows file sharing or FTP on the CNC: In Windows on the Mazak control, create a new user and share a folder or set up IIS FTP.

2. Make the CNC write logs: At the end of each part program (or in a scheduled routine), have the CNC save a text file to the share. Include status info like timestamp, cycle state, or count.

3. Watch the files on PC: On a PC, run a script that watches the shared folder for file changes. Parse new entries and log to a local database or CSV.

4. Analyze the batch data: Use this data to compute utilization, cycle counts, and uptime/downtime trends. Feed it into dashboards or spreadsheets.

Tools and Free Software

• MTConnect Agents: Free agents are available from open-source MTConnect projects. These poll the adapter and format XML.

• Dashboards: Grafana is a common choice for visualization. Node-RED can also fetch MTConnect XML and build web dashboards.

• Databases: InfluxDB, SQLite, or CSV files can be used to store data.

• Scripting: Use Python, PowerShell, or Bash for polling and parsing. Standard libraries or small tools can read logs or XML endpoints.

Limitations to Know

• Data Latency: MTConnect is near real-time; file polling is batch-based and slower.

• Data Scope: Free MTConnect may output only basic data items. File logs are limited to what the CNC writes.

• Controller Support: Older controls may not support MTConnect without hardware. Very old Mazaks may lack Ethernet entirely.

• Security: Be cautious when exposing CNCs to a network. Use a dedicated VLAN and limit external access.

From DIY to Professional Monitoring

Starting with these free methods gives visibility into uptime and OEE with zero license cost. As needs grow, you can layer in commercial tools or expand your pipeline. Once live data flows into a database, it's easy to scale up to include multiple machines or integrate more complex analytics.

About MDCplus

Our key features are real-time machine monitoring for swift issue resolution, power consumption tracking to promote sustainability, computerized maintenance management to reduce downtime, and vibration diagnostics for predictive maintenance. MDCplus's solutions are tailored for diverse industries, including aerospace, automotive, precision machining, and heavy industry. By delivering actionable insights and fostering seamless integration, we empower manufacturers to boost Overall Equipment Effectiveness (OEE), reduce operational costs, and achieve sustainable growth along with future planning.