Sensors in Machine Tools - Data Generation and Analysis - Output of Data Science - Productivity and Quality Engineering

 

Manufacturing Analytics - Introduction - Bibliography.

Machine Tool Analytics - Analytics for Machine Tools

Automation for Productivity and Cost Reduction  - Productivity Automation Engineering. - Lesson 112 of  Industrial Engineering ONLINE Course

A sensor is a device,  whose purpose is to detect events or changes in its environment and send the information to other electronic devices, frequently a computer processor.

Sensors are now in  in everyday objects such as touch-sensitive elevator buttons  and lamps which dim or brighten by touching the base.  With advances in micromachinery and easy-to-use microcontroller platforms, the uses of sensors have expanded beyond the traditional fields of temperature, pressure or flow measurement.   There are a wide range of sensors, measuring chemical & physical properties of materials. A few examples include optical sensors for Refractive index measurement, vibrational sensors for fluid viscosity measurement and electro-chemical sensor for monitoring pH of fluids.

Monitoring sensors

MOS monitoring sensors are used for house monitoring, office and agriculture monitoring, traffic monitoring (including car speed, traffic jams,), weather monitoring (such as for rain, wind, lightning and storms), defense monitoring, and monitoring temperature, humidity, air pollution, fire, health, security and lighting. MOS gas detector sensors are used to detect carbon monoxide, sulfur dioxide, hydrogen sulfide, ammonia, and other gas substances. Other MOS sensors include intelligent sensors and wireless sensor network (WSN) technology.

https://en.wikipedia.org/wiki/Sensor

Techniques of machine tool monitoring

Machine tool monitoring can be done with or without sensors. 

Using sensors, monitoring can be done by measuring:

the cutting force (with a multi-channel table dynamometer or rotating dynamometer)

vibration amplitude using multi-channel accelerometers

audible sound from the machining process

high-frequency sound or acoustic emission

Sensor-less machine tool monitoring is done by measuring internal drive signals such as:

feed motor current

spindle motor current

spindle power

Acoustic emission sensor

Machine tool monitoring is donewith Acoustic Emission (AE) sensors also. An AE sensor is commonly defined as the sound emitted as an elastic wave by a solid when it is deformed or struck, caused by the rapid release of localized stress energy. It is a  phenomenon which releases elastic energy into the material, which then propagates as an elastic wave. The detection frequency range of acoustic emission is from 1 kHz to 1 MHz. An AE sensor works on the principle of measuring the high-frequency energy signals produced during cutting process. It also measures the AE energy resulting from the fracture when a tool breaks.

https://en.wikipedia.org/wiki/CNC_machine_tool_monitoring_by_AE_sensors

Compact clamping stroke sensor for machine tools

08-12-2020

The inductive LDR-14-Z20 sensors are used for monitoring the clamping position in machine tools. The current clamping situation of the tool in a machine tool can be determined precisely by measuring the exact position of the shaft or spindle. This allows the tool to be clamped correctly which enables the highest machining quality, while minimizing the risk of damage.

https://www.micro-epsilon.in/news/2020/2020-12-08-indu-LDR-14/

Intelligent sensors in modern machine tools

PIOTR SZULEWSKI

DOMINIKA ŚNIEGULSKA-GRĄDZKA

MIROSŁAW NEJMAN *

Mechanik, No. 11 (2019)

DOI: https://doi.org/10.17814/mechanik.2019.11.91

Machine tool monitoring system

05 January 2019

The B-Safe machine tool monitoring system from Leader Chuck International is a new concept that supports the complete monitoring and diagnostics of spindles and machine tools using vibration and temperature analysis.

https://www.ipesearch.co.uk/Machine-tool-monitoring-system

Sensor-Based Control of Cutting Tools, Machine Tools Moves From Drawing Board to Mainstream

March 30, 2018

By Robert Puhr

Rigibore Inc. battery-powered ActiveEdge tool automates the in-process sizing of boring tool cutting edges. It uses wireless technology to remotely adjust multiple cutting edge diameters on a single tool, optimizing process performance and eliminating the need for operator intervention.

BadAxe Smart Tool assembly and software system replaces trial-and-error  to immediately hit the “sweet spot” of a machine when it is started up.  Using measurements of the resident vibration frequency patterns for a specific combination of machine, spindle, toolholder, and tool, the company’s patented algorithms and analytics calculate the optimum stability zone for the machine to operate in. The underlying technology has been proven to significantly increase a job’s ROI by organizations such as Boeing Phantom Works.

The Okuma Monitoring System allows up to 64 different inputs that can be customized to process-specific needs. By using the monitoring system, the operator can be alerted that there is a potential problem coming that preventative action can avoid.

Razor software can sift through vast amounts of data to find interrelationships and patterns that a human with a spreadsheet would never uncover. AI and ML technologies are used to develop models that help operators and managers arrive at clear conclusions very quickly—and take action based on data-driven conclusions.

Marposs  BLÚ is the result of over 50 years’ experience on grinding machines and other machine tools. It combines all the machine tool monitoring and process control applications in a single system for real-time tool and process monitoring, adaptive control, and crash mitigation with a fast processing and sampling time.

(Marposs Announces BLÚ LT Modular Control System for Machine Tools, March 18, 2021

Derived from the Marposs BLÚ single cable machine networking system, BLÚ LT provides the networkability of BLÚ, but at a more reasonable price point for less complex machine tool requirements.  This completes the company’s range of offerings for every type of installation, from the P1dME measuring system for the simplest grinding applications through BLÚ, capable of the most complex integrated production and control and created in line with the Internet of Things.

https://www.sme.org/technologies/articles/2021/march/marposs-announces-blu-lt-modular-control-system-for-machine-tools/)

Zenith provides feedback to the machine control to confirm that the tool has adjusted by the desired amount. This position sensor feedback prevents a bad part from being machined.

https://www.sme.org/technologies/articles/2018/march/sensor-based-control-of-cutting-tools-machine-tools-moves-from-drawing-board-to-mainstream/

QUANTITIES AND SENSORS FOR MACHINE TOOL SPINDLE CONDITION MONITORING 

LUDEK JANAK, JAKUB STETINA, ZDENEK FIALA, ZDENEK HADAS 

Brno University of Technology 

Faculty of Mechanical Engineering, Brno, Czech Republic 

DOI : 10.17973/MMSJ.2016_12_2016204

MM SCIENCE JOURNAL  2016,  DECEMBER

Development of a Machine Tool Diagnostic System Using Micro-Electromechanical System Sensors: A Case Study

Shang-Liang Chen, Yin-Ting Cheng, Zheng-Wei Lin and Yun-Yao Chen*

Institute of Manufacturing Information and Systems, National Cheng Kung University, 

No. 1, University Road, Tainan City 701, Taiwan (R.O.C.)

Sensors and Materials, Vol. 27, No. 8 (2015) 763–772

MYU Tokyo

Back propagation neural network is used to classify the spindle as in good condition or not.

 

Updated on 8,10,2021, 20 July 2021

Pub 10.7.2021