Online Conditions Monitoring of End-Mill Based on Sensor Integrated Smart Holder

摘要

End-mill damage causes the losses of surface smooth and dimensional accuracy for the machined part. In addition, offline monitoring of the end-mill conditions causes downtime and consequently reduce productive efficiency. In order to sense and monitor the conditions of end-mill in real time, an intelligent Internet of Things (IoT) system dedicated to online conditions monitoring of end-mill has been developed in this research work. The designed smart holder highly integrated with tri-axial acceleration sensor, Micro Controller Unit (MCU), wireless radio chip and battery is demonstrated. The system collects high resolution end-milling data during cutting without interfering with the machining process. In order to extract the data sequence containing the information highly related to the conditions of the end-mill, a simple but effective data extraction algorithm based on sinusoidal correlation is proposed. By real-time exploring the extracted data sequence via the developed data mining algorithm on the Computerized Numerical Control (CNC) edge server, the conditions of end-mill can be monitored online and consequently decision can be made in real time.