Development of a wireless system for milling temperature monitoring

Campidelli, Augusto; Lima, Hugo V.; Abrão, Alexandre Mendes; Maia, Antônio Augusto Torres

doi:10.1007/s00170-019-04088-0

Cited by 26 publications

(9 citation statements)

References 17 publications

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“…The common wireless technologies, utilized to transmit data to the host computer in TCM systems, include Wi-Fi [ 78 , 79 , 106 , 113 , 114 , 115 , 116 ], Bluetooth [ 82 , 95 , 117 , 118 ], and ZigBee [ 91 , 93 , 119 , 120 ]. Table 2 provides the specifications of the available wireless communication protocols used in the TCM systems [ 121 , 122 ].…”

Section: Sensing and Data Acquisitionmentioning

confidence: 99%

“…Other limiting factors that control the sampling rate are the speed of the microprocessor and the wired transmission protocols between the analog–digital converter (ADC) and the microcontroller. Therefore, the maximum transmission capacity of wireless networks is commonly not gained in most of the previous work [ 79 , 80 , 106 , 118 ]. The high sampling rate achieved in [ 20 ] ( Table 1 ) can be attributed to the utilization of the Serial Peripheral Interface SPI transmission protocol, which achieves high speeds compared to the Universal Asynchronous Receiver/Transmitter UART and the Inter-Integrated Circuit I 2 C protocols used in other designs.…”

Section: Sensing and Data Acquisitionmentioning

confidence: 99%

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Tool Condition Monitoring for High-Performance Machining Systems—A Review

Mohamed

Hassan

M’Saoubi³

et al. 2022

Sensors

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In the era of the “Industry 4.0” revolution, self-adjusting and unmanned machining systems have gained considerable interest in high-value manufacturing industries to cope with the growing demand for high productivity, standardized part quality, and reduced cost. Tool condition monitoring (TCM) systems pave the way for automated machining through monitoring the state of the cutting tool, including the occurrences of wear, cracks, chipping, and breakage, with the aim of improving the efficiency and economics of the machining process. This article reviews the state-of-the-art TCM system components, namely, means of sensing, data acquisition, signal conditioning and processing, and monitoring models, found in the recent open literature. Special attention is given to analyzing the advantages and limitations of current practices in developing wireless tool-embedded sensor nodes, which enable seamless implementation and Industrial Internet of Things (IIOT) readiness of TCM systems. Additionally, a comprehensive review of the selection of dimensionality reduction techniques is provided due to the lack of clear recommendations and shortcomings of various techniques developed in the literature. Recent attempts for TCM systems’ generalization and enhancement are discussed, along with recommendations for possible future research avenues to improve TCM systems accuracy, reliability, functionality, and integration.

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Section: Sensing and Data Acquisitionmentioning

confidence: 99%

Section: Sensing and Data Acquisitionmentioning

confidence: 99%

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Mohamed

Hassan

M’Saoubi³

et al. 2022

Sensors

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“…The authors successfully demonstrated temperature monitoring for milling of AISI P20 tool steel with a sensitivity of 0.173 μV/°C [ 3 ]. Campidelli et al investigated temperature monitoring during the milling of AISI D2 steel with TiN/TiCN coated carbide inserts [ 4 ]. A type-K thermocouple embedded within an indexable insert, near the cutting edge, was used to record the temperature.…”

Section: Introductionmentioning

confidence: 99%

“…Sensitivity to the variation of cutting parameters was demonstrated, with higher temperature corresponding to higher values of cutting speed and feed rate. At a cutting speed of 180 m/min, the embedded sensor recorded temperatures of 152, 163, and 180 °C at feed rates of 0.1, 0.2, and 0.3 mm/rev, respectively [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Boron Doped Diamond for Real-Time Wireless Cutting Temperature Monitoring of Diamond Coated Carbide Tools

et al. 2021

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Among the unique opportunities and developments that are currently being triggered by the fourth industrial revolution, developments in cutting tools have been following the trend of an ever more holistic control of manufacturing processes. Sustainable manufacturing is at the forefront of tools development, encompassing environmental, economic, and technological goals. The integrated use of sensors, data processing, and smart algorithms for fast optimization or real time adjustment of cutting processes can lead to a significant impact on productivity and energy uptake, as well as less usage of cutting fluids. Diamond is the material of choice for machining of non-ferrous alloys, composites, and ultrahard materials. While the extreme hardness, thermal conductivity, and wear resistance of CVD diamond coatings are well-known, these also exhibit highly auspicious sensing properties through doping with boron and other elements. The present study focuses on the thermal response of boron-doped diamond (BDD) coatings. BDD coatings have been shown to have a negative temperature coefficient (NTC). Several approaches have been adopted for monitoring cutting temperature, including thin film thermocouples and infrared thermography. Although these are good solutions, they can be costly and become impractical for certain finishing cutting operations, tool geometries such as rotary tools, as well as during material removal in intricate spaces. In the scope of this study, diamond/WC-Co substrates were coated with BDD by hot filament chemical vapor deposition (HFCVD). Scanning electron microscopy, Raman spectroscopy, and the van der Pauw method were used for morphological, structural, and electrical characterization, respectively. The thermal response of the thin diamond thermistors was characterized in the temperature interval of 20–400 °C. Compared to state-of-the-art temperature monitoring solutions, this is a one-step approach that improves the wear properties and heat dissipation of carbide tools while providing real-time and in-situ temperature monitoring.

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“…Due to the limitations of current wired sensor systems, and in order to reduce the invasion degree of sensor system into the milling or drilling process and increase flexibility, a series of wireless sensor-integrated systems for rotating cutter have been developed [8]- [23], in which the sensors and other electronic components, such as sensor signal processing module, wireless data transfer module, and power supply module, are all integrated into the tool holder. For the key wireless data transfer module, the common technologies, namely Bluetooth [8]- [11], ZigBee [12]- [14], WiFi [15]- [20], Radio frequency identification (RFID) [21] and sub-1 GHz radio frequency [22], [23], have been adopted to transmit the measured condition data wirelessly to a upper host computer. It can be noted that WiFi is the most widely used transmission method for tool condition monitoring, which has the potential to be competitor of other wireless transmission technologies taking into account of its relatively high transmission speed and long transmission distance.…”

Section: Introductionmentioning

confidence: 99%

Simultaneous Wireless Power and Data Transmission Over One Pair of Coils for Sensor-Integrated Rotating Cutter

Zhu

Tao

2020

IEEE Access

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Tool condition monitoring is becoming particularly important in the cutting process. More and more researchers start to integrate the sensors into the tool holder due to its convenient use and wide applicability. However, it is difficult to transmit out the condition data and supply stable power to the sensor-integrated systems through the traditional wired way as the tool holder is under high-speed rotation in milling or drilling process. In this paper, a novel simultaneous wireless power and data transfer system over one pair of coils for sensor-integrated rotating cutter is presented, and the eddy effect caused by the metal handle that impacts the system performance is solved with ferrite shielding. To transmit out the cutting condition data wirelessly, the synchronous detection and envelope detection technology are employed. Meanwhile, the synchronous rectification technology is adopted to improve the performance of the wireless power transfer. Eventually, the experimental platform has been set up and the cutting tests have also been carried out. The results show that the designed new wireless power and data transfer system over one pair of coils is stable and practical to track and transmit out the condition data of the rotating cutter. INDEX TERMS Tool condition monitoring, rotating cutter, simultaneous wireless power and data transfer, one pair of coils, ferrite shielding.

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Development of a wireless system for milling temperature monitoring

Cited by 26 publications

References 17 publications

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Boron Doped Diamond for Real-Time Wireless Cutting Temperature Monitoring of Diamond Coated Carbide Tools

Simultaneous Wireless Power and Data Transmission Over One Pair of Coils for Sensor-Integrated Rotating Cutter

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