Sensor Based Machine Tool Condition Monitoring System

Abstract

The benefits to the user of applying a Condition Monitoring (CM) system to a machine tool are improved system availability and reduction in scrap. Automatic Monitoring of critical operations is essential for unmanned machining. Automatic Diagnostics which identify the cause of any failure down to the relevant Line Replaceable Unit will substantially reduce down time. Automatic prediction of failures enables corrective maintenance to be planned into the production schedule. Research being undertaken at UWIST is aimed at producing a Condition Monitoring system with extensive Monitoring, Diagnostic and Predictive capabilities. The paper will detail the methodology involved in determining the Condition Monitoring Parameters. A pilot study on the machine tool coolant system will illustrate this methodology. The study will include choice of the monitoring parameters, evaluation development and application of sensors and the design of the Diagnostics and Monitoring Management system. Results obtained using a Wadkin V4-6 vertical milling machine as the test vehicle will be presented. The Condition Monitoring system will encompass all areas of the machine tool eg axis and spindle drives, hydraulics, controller etc. Work performed to date in these areas will also be presented.