Abstract
The performance of measurement or manufacturing systems in high-precision applications is dependent upon the dynamics of the system, as vibration can be a significant contributor to the measurement uncertainty and process variability. Technologies making use of accelerometers and laser vibrometers are available to rapidly measure and process structural dynamic data but the software infrastructure is yet to be available in an open source or standardised format to allow rapid inter-platform use. In this paper, we present a novel condition monitoring system, which uses commercially available accelerometers in combination with a control-monitoring infrastructure to allow for the appraisal of the performance of a measurement or manufacturing system. A field-programmable gate array (FPGA)-based control system is implemented for high-speed data acquisition and signal processing of six triaxial accelerometers, with a frequency range of 1 Hz to 6000 Hz, a sensitivity of 102.5 mV/ms−2 and a maximum sample rate of 12,800 samples per second per channel. The system includes two methods of operation: real-time performance monitoring and detailed measurement/manufacturing verification. A lathe condition monitoring investigation is undertaken to demonstrate the utility of this system and acquire typical machining performance parameters in order to monitor the “health” of the system.
Highlights
The importance of effective industrial measurement solutions to provide accurate and traceable parts is widely acknowledged [1,2]
The review presented here has shown that there are clear gaps in the literature in relation to live characterisation of measurement systems, and so we have developed a novel condition monitoring system which is capable of multipoint three axis condition monitoring and real-time data capture and analysis
Endevco 65L-100 triaxial integrated electronics piezoelectric (IEPE) accelerometers were selected for the system as they have a wide frequency range and can effectively measure vibration from selected for the system as they have a wide frequency range and can effectively measure vibration from laboratory and industrial sources likely to be seen in measurement systems, i.e., acoustic vibrations
Summary
The importance of effective industrial measurement solutions to provide accurate and traceable parts is widely acknowledged [1,2]. The tool condition monitoring is most widely performed using accelerometers, as they offer a practical solution which can be readily mounted to the system. Despite the promise of these methods, they were performed on milling machines which allow for sufficient space to enable mounting of the required measurement instruments with line-of-sight and without risk of being damaged by the swarf produced during the cutting process. Each of these approaches requires expensive equipment and have been used to obtain a single-point measurement Expanding these approaches to multipoint condition monitoring is cost prohibitive, and so the use of accelerometers remains the best solution at this stage. The system uses commercially available accelerometers in combination with a control-monitoring infrastructure to allow for the live appraisal of the performance of measurement mechanical structural elements, such as the camera and projector mounting tripod in a fringe projection system or the measurement stage of a focus variation system
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