Abstract
Nowadays, the condition-based maintenance (CBM), in which repairs are triggered by the heuristic symptoms of the component faults, is finding increasing applications in the industrial fields. However, for the high-precision machine tools, the conventional CBM might not be the optimal option, which is uneconomic and incapable of ensuring their machining accuracy. In order to overcome these shortcomings, this paper propose the manufacturing-error-based maintenance (MEBM), where the repairs are initiated based on the manufacturing errors instead of the heuristic symptoms. In MEBM, repairs are taken properly at the occurrence of the excessive machining errors, and therefore, the premature and redundant maintenance can be avoided and the maintenance cost can be minimized; what is more, the machining errors are controlled in the closed loops, and therefore, the machining accuracy can be guaranteed. Based on the principles of the MEBM, a prototype maintenance system—the transient backlash error (TBE)-based maintenance system—is established. To achieve this aim, first, the width of the backlash in the mechanical chain is measured by utilizing the built-in encoders and the analytical mapping relationship between the backlash width and the TBE is derived. Relying on these foundations, the TBE can be indirectly estimated. Then, the warning threshold of the TBE is customized according to the permissible roundness error of the workpiece. Thus, the maintenance actions can be precisely implemented: when the monitored TBE exceeds its warning threshold, maintenance workers will be notified to lessen the backlash width, and meanwhile, the permissible maximal size for the backlash will also be informed.
Highlights
Maintenance has become increasingly important and versatile in industrial field
It can be found that the manufacturing-error-based maintenance (MEBM) resembles a closed-loop control system, where the input of the maintenance system is the permissible machining error, the real-time machining error of the machine tool is monitored as the feedback
Based on the concept of MEBM, the transient backlash error (TBE)-based maintenance system can be developed as shown in Fig. 2, where the machining error caused by backlash is monitored, and compared with permissible machining error
Summary
Maintenance has become increasingly important and versatile in industrial field. For critical and fatal systems, such as aircrafts, submarines, and nuclear systems, preventative and predictive maintenance has been widely adopted to reduce the sudden stoppages, to achieve the reliability capabilities of the equipment and to minimize the catastrophic disasters [1]. By adopting different signals, like the vibration, acoustic emission (AE) and surface roughness, various condition monitoring techniques have been proposed for diagnosing the defects in the spindle bearings [13,14] From these aforementioned examples, it can be found that the reliability-centred CBM, originally proposed for the critical systems, is beneficial to improve the reliability and production quality of the production system: timely maintenance actions are generally taken once the heuristic symptoms for incipient faults are detected.
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