Basic computational tools and mechanical hardware for torque-based diagnostic of machining operations

In the industry, only rotary dynamometers can be used for monitoring when multiple spindles are used in machining operations. The current commercial rotary dynamometers are bulky and expensive for most machining centers. The basic hardware and computational tools proposed are for a smaller, more cost effective Torque-based Machining Monitor (TbMM). The objective of the TbMM concept is to estimate the remaining tool life, detect chatter from the torque signal inside the proposed device, and communicate with the central computer only when problems arise. The remaining tool life estimation and chatter detection algorithms of the TbMM were developed by analyzing the experimental data collected by a commercial rotary dynamometer. The mechanical hardware of the TbMM was designed to generate voltage proportional to the cutting torque using a piezoelectric composite element. The remaining tool life was estimated from the standard deviation (or variance) of the torque signal. Teager-Kaiser algorithm (TKA) based procedure detected the chatter based on the frequency estimations only from four samples at a time. The accuracy and characteristics of the signal of the mechanical component of the TbMM were found satisfactory in the estimation of machining problems such as wear and chatter. The TbMM is a good choice particularly when multiple spindles work simultaneously on the same workpiece

Basic computational tools and mechanical hardware for torque-based diagnostic of machining operations

In the industry, only rotary dynamometers can be used for monitoring when multiple spindles are used in machining operations. The current commercial rotary dynamometers are bulky and expensive for most machining centers. The basic hardware and computational tools proposed are for a smaller, more cost effective Torque-based Machining Monitor (TbMM). The objective of the TbMM concept is to estimate the remaining tool life, detect chatter from the torque signal inside the proposed device, and communicate with the central computer only when problems arise. The remaining tool life estimation and chatter detection algorithms of the TbMM were developed by analyzing the experimental data collected by a commercial rotary dynamometer. The mechanical hardware of the TbMM was designed to generate voltage proportional to the cutting torque using a piezoelectric composite element. The remaining tool life was estimated from the standard deviation (or variance) of the torque signal. Teager-Kaiser algorithm (TKA) based procedure detected the chatter based on the frequency estimations only from four samples at a time. The accuracy and characteristics of the signal of the mechanical component of the TbMM were found satisfactory in the estimation of machining problems such as wear and chatter. The TbMM is a good choice particularly when multiple spindles work simultaneously on the same workpiece

Diagnosis of Machining Conditions Based on Logical Analysis of Data

RÉSUMÉ : Un élément clé pour un système d'usinage automatisé sans surveillance est le développement de systèmes de surveillance et de contrôle fiables et robustes. Plusieurs modèles mathématiques et statistiques, qui modélisent la relation entre les variables indépendantes et les variables dépendantes d’usinage, sont suggérés dans la littérature, en commençant par le modèle de Taylor jusqu’aux modèles de régression les plus sophistiqués. Tous ces modèles ne sont pas dynamiques, dans le sens que leurs paramètres ne changent pas avec le temps. Des modèles basés sur l'intelligence artificielle ont résolu de nombreux problèmes dans ce domaine, mais la recherche continue. Dans la présente thèse, je propose l'application d'une approche appelée Analyse Logique de Données (LAD) pour prédire le sortant d’un processus d’usinage. Cette approche a démontré une bonne performance et des capacités additionnelles une fois comparée à la conception traditionnelle des expériences ou à la modélisation mathématique et statistique. Elle est aussi comparée dans cette thèse à la méthode bien connue des réseaux de neurones. Elle est basée sur l'exploitation des données saisies par des capteurs et l'extraction des informations utiles à partir de ces dernières. LAD est utilisé pour déterminer les meilleures conditions d'usinage, pour détecter l'usure de l'outil, pour identifier le moment optimal de remplacement de l’outil d’usinage, et pour surveiller et contrôler les processus d'usinage. Étant donné que les capteurs et les technologies de l'information sont tous les deux en expansion rapide et continue, il serait prévu qu'un outil d’analyse tels que LAD aidera à tracer un chemin dans l'amelioration des processus d'usinage en utilisant les techniques de pointe afin de réduire considérablement le coût ces processus. Les résultats de mon travail pourraient avoir un impact important sur l'optimisation de ces processus.----------ABSTRACT : A key issue for an unattended and automated machining system is the development of reliable and robust monitoring and controlling systems. Research in Artificial Intelligence-based monitoring of machining systems covers several issues and has solved many problems, but the search continues for a robust technique that does not depend on a statistical learning background and that does not have ambiguous procedures. In this thesis, I propose the application of an approach called Logical Analysis of Data (LAD) which is based on the exploitation of data captured by sensors, and the extraction of useful information from this data. LAD is used for determining the best machining conditions, detecting the tool wear, identifying the optimal replacement time for machining tools, monitoring, and controlling machining processes. LAD has demonstrated good performance and additional capabilities when it is compared to the famous statistical technique, Proportional Hazard Model (PHM), and the well known machine learning technique, Artificial Neural Network (ANN). Since sensors’ and information technologies are both expanding rapidly and continuously, it is expected that an analysis tool such as LAD will help in blazing a new trail in machining processes by using state of the art techniques in order to significantly reduce the cost of machining process