Data analytics plays a significant role in the realization of Industry 4.0. By generating context-related persistent datasets, every manufacturing process in real production becomes an experiment. The vision of Internet of Production (IoP) is to enable real-time diagnosis and prediction in smart productions by acquiring datasets seamlessly from different data silos. This requires interdisciplinary collaboration and domain-specific expertise. In this paper, we present a novel tool wear monitoring system for milling process developed in the context of IoP. This system is based on high-frequency data from the numerical control of the production machine without additional sensors. The novelty of this paper lies in the introduction of virtual workpiece quality and fusion of multiple build-in sensor signals and a force model as decision support. This bridges the time gap between quality inspection and production at the shop floor level, establishes an automated statistical process control system, and provides a more plausible prediction of tool lifetime. The monitoring of two different milling processes in a real production environment is exemplary demonstrated in this paper. The first case is a face roughing process with the aim of rapidly removing large amounts of material. The second case is a face finishing operation that follows roughing and aims to achieve the desired surface quality.
Numerische Steuerungen für Werkzeugmaschinen erfassen eine erhebliche Menge an Sensordaten für die Achsregelung. Diese liefern nicht nur Informationen über die aktuellen Achspositionen oder die Ströme, sondern können mithilfe von Modellen auch für das Monitoring von anderen Prozessgrößen verwendet werden. In diesem Beitrag wird ein Machine-Learning-Verfahren zur Überwachung von Werkzeugverschleiß untersucht, welches allein auf maschinen-internen Daten basiert. Numerical controls for machine tools acquire a considerable amount of sensor data for axis control. This information, such as the current axis position or the motor currents, can be used for monitoring other process variables with the aid of models. This article investigates a machine learning method for monitoring tool wear in machine tools, based on machine-internal data only.
Numerische Steuerungen für Werkzeugmaschinen erfassen eine erhebliche Menge an Sensordaten für die Achsregelung. Diese liefern nicht nur Informationen über die aktuellen Achspositionen oder die Ströme, sondern können mithilfe von Modellen auch für das Monitoring von anderen Prozessgrößen verwendet werden. Vorgestellt wird ein Machine-Learning-Verfahren zur Überwachung von Werkzeugverschleiß, welches allein auf maschinen-internen Daten basiert.
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