Empirical Mode Decomposition of Pressure Signal for Health Condition Monitoring in Waterjet Cutting

Waterjet/abrasive waterjet cutting is a flexible technology that can be exploited for different operations on a wide range of materials. Due to challenging pressure conditions, cyclic pressure loadings, and aggressiveness of abrasives, most of the components of the ultra-high pressure (UHP) pump and the cutting head are subject to wear and faults that are difficult to predict. Therefore, the continuous monitoring of machine health conditions is of great industrial interest, as it allows implementing condition-based maintenance strategies, and providing an automatic reaction to critical faults, as far as unattended processes are concerned. Most of the literature in this frame is focused on indirect workpiece quality monitoring and on fault detection for critical cutting head components (e.g., orifices and mixing tubes). A very limited attention has been devoted to the condition monitoring of critical UHP pump components, including cylinders and valves. The paper investigates the suitability of the water pressure signal as a source of information to detect different kinds of fault that may affect both the cutting head and the UHP pump components. We propose a condition monitoring approach that couples empirical mode decomposition (EMD) with principal component analysis to detect any pattern deviation with respect to a reference model, based on training data. The EMD technique is used to separate high-frequency transient patterns from low-frequency pressure ripples, and the computation of combined mode functions is applied to cope with the mode mixing effect. Real industrial data, acquired under normal working conditions and in the presence of actual faults, are used to demonstrate the performances provided by the proposed approach

A Probabilistic-Based Approach to Monitoring Tool Wear State and Assessing Its Effect on Workpiece Quality in Nickel-Based Alloys

The objective of this research is first to investigate the applicability and advantage of statistical state estimation methods for predicting tool wear in machining nickel-based superalloys over deterministic methods, and second to study the effects of cutting tool wear on the quality of the part. Nickel-based superalloys are among those classes of materials that are known as hard-to-machine alloys. These materials exhibit a unique combination of maintaining their strength at high temperature and have high resistance to corrosion and creep. These unique characteristics make them an ideal candidate for harsh environments like combustion chambers of gas turbines. However, the same characteristics that make nickel-based alloys suitable for aggressive conditions introduce difficulties when machining them. High strength and low thermal conductivity accelerate the cutting tool wear and increase the possibility of the in-process tool breakage. A blunt tool nominally deteriorates the surface integrity and damages quality of the machined part by inducing high tensile residual stresses, generating micro-cracks, altering the microstructure or leaving a poor roughness profile behind. As a consequence in this case, the expensive superalloy would have to be scrapped. The current dominant solution for industry is to sacrifice the productivity rate by replacing the tool in the early stages of its life or to choose conservative cutting conditions in order to lower the wear rate and preserve workpiece quality. Thus, monitoring the state of the cutting tool and estimating its effects on part quality is a critical task for increasing productivity and profitability in machining superalloys. This work aims to first introduce a probabilistic-based framework for estimating tool wear in milling and turning of superalloys and second to study the detrimental effects of functional state of the cutting tool in terms of wear and wear rate on part quality. In the milling operation, the mechanisms of tool failure were first identified and, based on the rapid catastrophic failure of the tool, a Bayesian inference method (i.e., Markov Chain Monte Carlo, MCMC) was used for parameter calibration of tool wear using a power mechanistic model. The calibrated model was then used in the state space probabilistic framework of a Kalman filter to estimate the tool flank wear. Furthermore, an on-machine laser measuring system was utilized and fused into the Kalman filter to improve the estimation accuracy. In the turning operation the behavior of progressive wear was investigated as well. Due to the nonlinear nature of wear in turning, an extended Kalman filter was designed for tracking progressive wear, and the results of the probabilistic-based method were compared with a deterministic technique, where significant improvement (more than 60% increase in estimation accuracy) was achieved. To fulfill the second objective of this research in understanding the underlying effects of wear on part quality in cutting nickel-based superalloys, a comprehensive study on surface roughness, dimensional integrity and residual stress was conducted. The estimated results derived from a probabilistic filter were used for finding the proper correlations between wear, surface roughness and dimensional integrity, along with a finite element simulation for predicting the residual stress profile for sharp and worn cutting tool conditions. The output of this research provides the essential information on condition monitoring of the tool and its effects on product quality. The low-cost Hall effect sensor used in this work to capture spindle power in the context of the stochastic filter can effectively estimate tool wear in both milling and turning operations, while the estimated wear can be used to generate knowledge of the state of workpiece surface integrity. Therefore the true functionality and efficiency of the tool in superalloy machining can be evaluated without additional high-cost sensing

A New Approach to Evaluation of the Material Cutting Using the Artificial Neural Networks

Article deals with the process of accurate measurements and evaluation, i.e. the monitoring of the technological process of the material cutting using the Abrasive Water Jet and process control while using the artificial neural network, and a suggestion of process steps, particularly by a thorough application of mathematical modelling principles. An important mission of this article is to document, in an easy and comprehensible way, a tool intended for the creation of good control properties for multiple axes of the material cutting head support (using the AWJ, Plasma, acetylene burner, etc.). A desired objective is to achieve the best possible or optimal quality of the surface of the cut material, while using the properties of modern cutting technologies. To achieve those objectives, one of several known options was applied, in particular the advantages of the artificial neural networks and their beneficial properties. A simple task will be used to practically document the behaviour of an artificial neural network and a selected model execution

Profile monitoring via sensor fusion: The use of PCA methods for multi-channel data

Continuous advances of sensor technology and real-time computational capability are leading to data-rich environments to improve industrial automation and machine intelligence. When multiple signals are acquired from different sources (i.e. multi-channel signal data), two main issues must be faced: (i) the reduction of data dimensionality to make the overall signal analysis system efficient and actually applicable in industrial environments, and (ii) the fusion of all the sensor outputs to achieve a better comprehension of the process. In this frame, multi-way principal component analysis (PCA) represents a multivariate technique to perform both the tasks. The paper investigates two main multi-way extensions of the traditional PCA to deal with multi-channel signals, one based on unfolding the original data-set, and one based on multi-linear analysis of data in their tensorial form. The approaches proposed for data modelling are combined with appropriate control charting to achieve multi-channel profile data monitoring. The developed methodologies are demonstrated with both simulated and real data. The real data come from an industrial sensor fusion application in waterjet cutting, where different signals are monitored to detect faults affecting the most critical machine components

Friction, Vibration and Dynamic Properties of Transmission System under Wear Progression

This reprint focuses on wear and fatigue analysis, the dynamic properties of coating surfaces in transmission systems, and non-destructive condition monitoring for the health management of transmission systems. Transmission systems play a vital role in various types of industrial structure, including wind turbines, vehicles, mining and material-handling equipment, offshore vessels, and aircrafts. Surface wear is an inevitable phenomenon during the service life of transmission systems (such as on gearboxes, bearings, and shafts), and wear propagation can reduce the durability of the contact coating surface. As a result, the performance of the transmission system can degrade significantly, which can cause sudden shutdown of the whole system and lead to unexpected economic loss and accidents. Therefore, to ensure adequate health management of the transmission system, it is necessary to investigate the friction, vibration, and dynamic properties of its contact coating surface and monitor its operating conditions

Prediction of Robot Execution Failures Using Neural Networks

In recent years, the industrial robotic systems are designed with abilities to adapt and to learn in a structured or unstructured environment. They are able to predict and to react to the undesirable and uncontrollable disturbances which frequently interfere in mission accomplishment. In order to prevent system failure and/or unwanted robot behaviour, various techniques have been addressed. In this study, a novel approach based on the neural networks (NNs) is employed for prediction of robot execution failures. The training and testing dataset used in the experiment consists of forces and torques memorized immediately after the real robot failed in assignment execution. Two types of networks are utilized in order to find best prediction method - recurrent NNs and feedforward NNs. Moreover, we investigated 24 neural architectures implemented in Matlab software package. The experimental results confirm that this approach can be successfully applied to the failures prediction problem, and that the NNs outperform other artificial intelligence techniques in this domain. To further validate a novel method, real world experiments are conducted on a Khepera II mobile robot in an indoor structured environment. The obtained results for trajectory tracking problem proved usefulness and the applicability of the proposed solution

Neural Extended Kalman Filter for State Estimation of Automated Guided Vehicle in Manufacturing Environment

To navigate autonomously in a manufacturing environment Automated Guided Vehicle (AGV) needs the ability to infer its pose. This paper presents the implementation of the Extended Kalman Filter (EKF) coupled with a feedforward neural network for the Visual Simultaneous Localization and Mapping (VSLAM). The neural extended Kalman filter (NEKF) is applied on-line to model error between real and estimated robot motion. Implementation of the NEKF is achieved by using mobile robot, an experimental environment and a simple camera. By introducing neural network into the EKF estimation procedure, the quality of performance can be improved

A System and Method for Monitoring Controlling and Troubleshooting of Abrasive Waterjet Cutting Apparatus

The invention consists of a system and method for monitoring, controlling and troubleshooting of Abrasive Waterjet Cutting machinery. More in detail, the method exploits a network of sensors for continuously monitor its vibroacoustic emission pattern. Relevant features are extracted from the data using an iterative processing method. Deviations from a benchmark are interpreted based on model training then used for automatic control and troubleshooting. The expected outcome is an improvement of waterjet automation and robustness to the excellence of Industry 4.0 with a consequent impact on both its cost effectiveness and the provided quality assurance

Artificial cognitive architecture with self-learning and self-optimization capabilities. Case studies in micromachining processes

Tesis doctoral inédita leída en la Universidad Autónoma de Madrid, Escuela Politécnica Superior, Departamento de Ingeniería Informática. Fecha de lectura : 22-09-201

Smart Sensor Monitoring in Machining of Difficult-to-cut Materials

The research activities presented in this thesis are focused on the development of smart sensor monitoring procedures applied to diverse machining processes with particular reference to the machining of difficult-to-cut materials. This work will describe the whole smart sensor monitoring procedure starting from the configuration of the multiple sensor monitoring system for each specific application and proceeding with the methodologies for sensor signal detection and analysis aimed at the extraction of signal features to feed to intelligent decision-making systems based on artificial neural networks. The final aim is to perform tool condition monitoring in advanced machining processes in terms of tool wear diagnosis and forecast, in the perspective of zero defect manufacturing and green technologies. The work has been addressed within the framework of the national MIUR PON research project CAPRI, acronym for “Carrello per atterraggio con attuazione intelligente” (Landing Gear with Intelligent Actuation), and the research project STEP FAR, acronym for “Sviluppo di materiali e Tecnologie Ecocompatibili, di Processi di Foratura, taglio e di Assemblaggio Robotizzato” (Development of eco-compatible materials and technologies for robotised drilling and assembly processes). Both projects are sponsored by DAC, the Campania Technological Aerospace District, and involve two aerospace industries, Magnaghi Aeronautica S.p.A. and Leonardo S.p.A., respectively. Due to the industrial framework in which the projects were developed and taking advantage of the support from the industrial partners, the project activities have been carried out with the aim to contribute to the scientific research in the field of machining process monitoring as well as to promote the industrial applicability of the results. The thesis was structured in order to illustrate all the methodologies, the experimental tests and the results obtained from the research activities. It begins with an introduction to “Sensor monitoring of machining processes” (Chapter 2) with particular attention to the main sensor monitoring applications and the types of sensors which are employed in machining. The key methods for advanced sensor signal processing, including the implementation of sensor fusion technology, are discussed in details as they represent the basic input for cognitive decision-making systems construction. The chapter finally presents a brief discussion on cloud-based manufacturing which will represent one of the future developments of this research work. Chapters 3 and 4 illustrate the case studies of machining process sensor monitoring investigated in the research work. Within the CAPRI project, the feasibility of the dry turning process of Ti6Al4V alloy (Chapter 3) was studied with particular attention to the optimization of the machining parameters avoiding the use of coolant fluids. Since very rapid tool wear is experienced during dry machining of Titanium alloys, the multiple sensor monitoring system was used in order to develop a methodology based on a smart system for on line tool wear detection in terms of maximum flank wear land. Within the STEP FAR project, the drilling process of carbon fibre reinforced (CFRP) composite materials was studied using diverse experimental set-ups. Regarding the tools, three different types of drill bit were employed, including traditional as well as innovative geometry ones. Concerning the investigated materials, two different types of stack configurations were employed, namely CFRP/CFRP stacks and hybrid Al/CFRP stacks. Consequently, the machining parameters for each experimental campaign were varied, and also the methods for signal analysis were changed to verify the performance of the different methodologies. Finally, for each case different neural network configurations were investigated for cognitive-based decision making. First of all, the applicability of the system was tested in order to perform tool wear diagnosis and forecast. Then, the discussion proceeds with a further aim of the research work, which is the reduction of the number of selected sensor signal features, in order to improve the performance of the cognitive decision-making system, simplify modelling and facilitate the implementation of these methodologies in a cloud manufacturing approach to tool condition monitoring. Sensor fusion methodologies were applied to the extracted and selected sensor signal features in the perspective of feature reduction with the purpose to implement these procedures for big data analytics within the Industry 4.0 framework. In conclusion, the positive impact of the proposed tool condition monitoring methodologies based on multiple sensor signal acquisition and processing is illustrated, with particular reference to the reliable assessment of tool state in order to avoid too early or too late cutting tool substitution that negatively affect machining time and cost