Low-Cost Precision Monitoring System of Machine Tools for SMEs

Xing, Kanglin; Liu, Xiaojie; Liu, Zhaoheng; Mayer, Josef; Achiche, Sofiane

doi:10.1016/j.procir.2021.01.098

Cited by 19 publications

(9 citation statements)

References 17 publications

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“…Likewise, single-phase spindle currents are measured to monitor the health state of a feed drive [51]. Alternative sensing methods include the use of Hall effect sensors [52], cameras [53], an inertial measurement unit (IMU) [54][55][56][57][58], piezoresistive materials [59][60][61][62], strain gauges [61,63,64], and tactile load cells [65].…”

Section: Condition Monitoringmentioning

confidence: 99%

“…Current [72,73], torque [73] Vibration [38,40,74,75] PSD [40], OT [75], STFT [38,40], HHT [74,72,73], MSE [74,72,73] Backlash -Vibration [76], camera [53] Statistical [53], FFT [76] Fault detection/ diagnosis -Vibration [77] PCT [77] Prognosis/RUL --Sensing methods/ technologies -Wireless vibration [78], hybrid sensor [46] FFT [78], OT [46] Other methods Linear encoder [79,80], torque [80,81] -Statistical [81], FFT [79,80] Linear guide/slide Wear/degradation Rotary encoder [82], linear encoder [82], current [82,83] IMU [56][57][58], ball-end probe [83] Statistical [56,58,83], EMD [82], filtering [57] Preload and force -Vibration…”

Section: Preload Lossmentioning

confidence: 99%

“…The important factor with respect to the frequency is the position control loop gain. Xing et al [53] present a low-cost monitoring solution that can be implemented in small and mediumsized enterprises. A camera mounted on a machining center captures pictures of NC compensation parameters, such as backlash, pitch, and straightness error compensation.…”

Section: Backlash Monitoringmentioning

confidence: 99%

“…Several alternative sensing methods and technologies include the use of MEMS sensors for monitoring preload and machine tool health [38][39][40][41] and the use of a camera for monitoring NC parameters related to the health of a ball screw [53].…”

Section: 16mentioning

confidence: 99%

See 3 more Smart Citations

Condition Monitoring of Machine Tool Feed Drives: A Review

Butler

Ziada

Stephenson

et al. 2022

Journal of Manufacturing Science and Engineering

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The innovations propelling the manufacturing industry towards Industry 4.0 have begun to maneuver into machine tools. Machine tool maintenance primarily concerns the feed drives used for workpiece and tool positioning. Condition monitoring of feed drives is the intermediate step between smart data acquisition and evaluating machine health through diagnostics and prognostics. This review outlines the techniques and methods that recent research presents for feed drive condition monitoring, diagnostics and prognostics. The methods are distinguished between being sensorless and sensor-based, as well as between signal-, model- and machine learning-based techniques. Close attention is given to the components of feed drives (ball screws, linear guideways and rotary axes) and the most notable parameters used for monitoring. Commercial and industry solutions to Industry 4.0 condition monitoring are described and detailed. The review is concluded with a brief summary and the observed research gaps.

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Section: Condition Monitoringmentioning

confidence: 99%

Section: Preload Lossmentioning

confidence: 99%

Section: Backlash Monitoringmentioning

confidence: 99%

Section: 16mentioning

confidence: 99%

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Condition Monitoring of Machine Tool Feed Drives: A Review

Butler

Ziada

Stephenson

et al. 2022

Journal of Manufacturing Science and Engineering

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“…The method consists of analyzing the most influential parameters on the overall machining cost and then determining the best set of parameters to minimize this. Cost optimization is a common research topic, either by the implementation of optimal parameters or by monitoring tool behavior, such as a monitoring system [28], which can also be used to determine the economic impact of the process itself [29]. To optimize the cost of the machining processes, there have been some applications developed for this purpose, with cost estimations based on machining times, as proposed by Ben-Arieh and Li [30], where a web-based application, based on the Java 2 Enterprise Edition was developed.…”

Section: Introductionmentioning

confidence: 99%

Build-Up an Economical Tool for Machining Operations Cost Estimation

Silva

Sousa

Pinto

et al. 2022

Metals

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Currently, there is a lack of affordable and simple tools for the estimation of these costs, especially for machining operations. This is particularly true for manufacturing SMEs, in which the cost estimation of machined parts is usually performed based only on required material for part production, or involves a time-consuming, non-standardized technical analysis. Therefore, a cost estimation tool was developed, based on the calculated machining times and amount of required material, based on the final drawing of the requested workpiece. The tool was developed primarily for milling machines, considering milling, drilling, and boring/threading operations. Regarding the considered materials, these were primarily aluminum alloys. However, some polymer materials were also considered. The tool first estimates the required time for total part production and then calculates the total cost. The total production time is estimated based on the required machining operations, as well as drawing, programming, and machine setup time. A part complexity level was also introduced, based on the number of details and operations required for each workpiece, which will inflate the estimated times. The estimation tool was tested in a company setting, comparing the estimated operation time values with the real ones, for a wide variety of parts of differing complexity. An average error of 14% for machining operation times was registered, which is quite satisfactory, as this time is the most impactful in terms of machining cost. However, there are still some problems regarding the accuracy in estimating finishing operation times.

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