Simulation based Process Monitoring for Single Item Production without Machine External Sensors

Denkena, Berend; Fischer, Ruben; Euhus, Dirk; Neff, Thomas

doi:10.1016/j.protcy.2014.09.088

Cited by 12 publications

(5 citation statements)

References 5 publications

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“…Finally, during machine tool usage period, process will be under control by the monitoring of the most important variables and the possibility to include simplified versions of the Digital Twin of the machine tool to perform model-based control actions [3]. According to machine tool health management, both local and fleet-level tasks will be implemented.…”

Section: Real Machine Tool Life-cyclementioning

confidence: 99%

“…The proposed monitoring hardware is the best environment to do this integration. For example, the integration of process models with real monitored data could be used for process monitoring [3], replacing the learning stage when it is not feasible, for example, in aerospace applications where batches are normally small.…”

Section: Local Monitoring and Control Systemmentioning

confidence: 99%

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Twin-Control Approach

et al. 2019

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Twin-Control (http://twincontrol.eu/) is a novel concept for machine tool and machining process performance optimization. It combines several features in the field of ICTs in manufacturing towards a better performance of machine tools [1]. A holistic simulation model, a so-called Digital Twin [2] of the machine tool, integrating most important features of machine tools and machining process, is combined with monitoring and data management capabilities. Twin-Control will use a Digital Twin concept for the development of the simulation tool (Fig. 2.1). The Digital Twin is based on a combined application of the Cyber and Physical worlds, following the cyber-physical system (CPS) concept. The Cyber world consists in the computation, communication and control systems. The Physical world is composed by the natural and human-made systems governed by the laws of physics. A Digital Twin of the machine tool resulting from the combination of the different theoretical models that cover different aspects of the manufacturing process corresponds to the Cyber world, together with the cloud-based data management part,

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Section: Real Machine Tool Life-cyclementioning

confidence: 99%

Section: Local Monitoring and Control Systemmentioning

confidence: 99%

Twin-Control Approach

et al. 2019

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“…The novel aspect is the use of OK-process data of one or more source machines to calculate statistical monitoring limits for the target machine, that are suited for online monitoring. As research exists on process segmentation [11][12][13] and process force reconstruction [3,14], the focus is subsequently on the transfer of knowledge between machines.…”

Section: Introductionmentioning

confidence: 99%

Transfer of Process References between Machine Tools for Online Tool Condition Monitoring

2021

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Process and tool condition monitoring systems are a prerequisite for autonomous production. One approach to monitoring individual parts without complex cutting simulations is the transfer of knowledge among similar monitoring scenarios. This paper introduces a novel monitoring method which transfers monitoring limits for process signals between different machine tools. The method calculates monitoring limits statistically from cutting processes carried out on one or more similar machines. The monitoring algorithm aims to detect general process anomalies online. Experiments comprise face-turning operations at five different lathes, four of which were of the same model. Results include the successful transfer of monitoring limits between machines of the same model for the detection of material anomalies. In comparison to an approach based on dynamic time warping (DTW) and density-based spatial clustering of applications with noise (DBSCAN), the new method showed fewer false alarms and higher detection rates. However, for the transfer between different models of machines, the successful application of the new method is limited. This is predominantly due to limitations of the employed process component isolation and differences between machine models in terms of signal properties as well as execution speed.

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“…Another key principle of Industry 4.0 is to increase the knowledge of the process obtained through monitoring (Lee et al 2015). This knowledge can be applied, for example, for process control (Denkena et al 2014) and maintenance actions optimization (Alzaga et al 2014). The combination of models and process monitoring will be useful not only in the development and design stages, but mainly during the production stage in order to check that production is running smoothly, detect wear and tear without needing to halt production or predict component failure and other disruptions.…”

Section: Introductionmentioning

confidence: 99%

Twin-Control: A New Concept Towards Machine Tool Health Management

Armendia

Peysson

Euhus³

2016

PHME_CONF

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Twin-Control (http://twincontrol.eu/) is a new concept for machine tool and machining process performance optimization. It is based on a new simulation model that integrates the different aspects that affect machine tool and machining performance. This holistic approach will allow a better estimation of machining performance than single featured simulation packages, including lifecycle concepts like energy consumption and end-life of components.This theoretical representation of the machine is complemented with real process data by the monitoring of the most important variables of the machining process and machine condition. This monitored information, combined with the developed models, is used at machine level to perform model-based control actions and/or warn about damaged components of the machine tool. In addition, a fleet-level data management system is used for a proper health management and optimize the maintenance actions on the machine tools.

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Simulation based Process Monitoring for Single Item Production without Machine External Sensors

Cited by 12 publications

References 5 publications

Twin-Control Approach

Twin-Control Approach

Transfer of Process References between Machine Tools for Online Tool Condition Monitoring

Twin-Control: A New Concept Towards Machine Tool Health Management

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