Abstract
Surface acoustic wave sensors offer overwhelming advantages over other potentially competitive sensing technologies in rotating mechanical structures for their wireless and passive capability. Nevertheless, the challenges of using these sensors have not been adequately addressed. Radio frequency signal of surface acoustic wave sensors acts as not only the role of data transmission but also the role of energy supply during the sensing system working process. Thus, the performance of surface acoustic wave sensors when they are used to monitor rotating spindles should be investigated due to the harsh metallic environments for radio propagation in machine tool. This article aims to experimentally study the performance of surface acoustic wave sensors on both rotating spindle with Computer Numerical Control machine tool and self-developed spindle apparatus. The measurement study is performed using a temperature surface acoustic wave sensor working in the Industrial Scientific and Medical (ISM) band (433.05–434.79 MHz). Experimental results have shown that transmission and measurement characteristics were closely depended on the surface acoustic wave sensor installation location and rotation speeds. The conclusions will directly guide the sensor location optimization, power setting, errors avoidance, or correction in the future work.
Highlights
Advanced sensor system design and their integration into machine tools enable improved understanding of the process conditions and facilitate optimization and control of the part quality.[1,2] Spindle units in machine tools, built within totally closed metallic shells, are among those hard-to-reach structures having crucial monitoring importance.[3]
As the first attempt to systematically investigate the transmission and measurement performance of surface acoustic wave (SAW) sensor in manufacturing environment, a series of experiments were executed on a Computer Numerical Control (CNC) machine tool and the self-developed spindle apparatus
(1) Interrogator antenna installation location has a significant influence on SAW sensors performance
Summary
Advanced sensor system design and their integration into machine tools enable improved understanding of the process conditions and facilitate optimization and control of the part quality.[1,2] Spindle units in machine tools, built within totally closed metallic shells, are among those hard-to-reach structures having crucial monitoring importance.[3]. Using wireless sensors is a good solution for condition monitoring, the sensors’ power supply is another key factor to be considered, especially for the spindle unit in an enclosure structure. The SAWs are generated by the IDT and are reflected by the reflectors to form a standing wave pattern, causing resonance. The shift in the resonance frequency of the resonator generated with the varying piezoelectric plate physical characters, caused by external factors, such as the temperature, strain, and torque.[19] The required parameters can be obtained by measuring the shift of the center frequency. The interrogator configured by the server (Figure 1(c)) originally, including the number of interrogator antennas and SAW sensors, the sampling intervals, and RF signal frequencies, and the interrogator unit sends out RF signal (electromagnetic wave) at a specific frequency and over a given time period toward the SAW sensor
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