Abstract
Abstract Effective monitoring of a manufacturing process is essential for ensuring product quality. Single-sensor systems have often proven not to be very effective due to the relatively large number of parameters and the complexity of machining processes. Multi-sensor systems have therefore been investigated in recent years to improve the reliability of tool failure monitoring. This paper outlines a fundamental theory (“Mapping Theory”) that will form a framework for selecting an appropriate monitoring system for any given machining system. In particular, such a theory should facilitate development of monitoring systems for reconfigurable machining. Presented are the concepts of Fault, Sensor, Signal Processing, and Computing Spaces, and their generic characteristics. Study of their fundamental properties reveals that there are certain levels of uncertainty involved in describing them. This has led to the adoption of fuzzy systems theory as a fundamental tool for development of the “Mapping Theory.” This article reports on recent progress made in this regard and outlines some of the preliminary results obtained. It is shown that, based on the characteristics of the faults and the type of machining operations, it is possible to rank the sensors based on their characteristics and to come up with an appropriate multi-sensor monitoring system. Examples are provided to show the effectiveness of the approach.
Published Version
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