FPGA-Based Fused Smart-Sensor for Tool-Wear Area Quantitative Estimation in CNC Machine Inserts

Manufacturing processes are of great relevance nowadays, when there is a constant claim for better productivity with high quality at low cost. The contribution of this work is the development of a fused smart-sensor, based on FPGA to improve the online quantitative estimation of flank-wear area in CNC machine inserts from the information provided by two primary sensors: the monitoring current output of a servoamplifier, and a 3-axis accelerometer. Results from experimentation show that the fusion of both parameters makes it possible to obtain three times better accuracy when compared with the accuracy obtained from current and vibration signals, individually used

A Field Programmable Gate Array-Based Reconfigurable Smart-Sensor Network for Wireless Monitoring of New Generation Computer Numerically Controlled Machines

Computer numerically controlled (CNC) machines have evolved to adapt to increasing technological and industrial requirements. To cover these needs, new generation machines have to perform monitoring strategies by incorporating multiple sensors. Since in most of applications the online Processing of the variables is essential, the use of smart sensors is necessary. The contribution of this work is the development of a wireless network platform of reconfigurable smart sensors for CNC machine applications complying with the measurement requirements of new generation CNC machines. Four different smart sensors are put under test in the network and their corresponding signal processing techniques are implemented in a Field Programmable Gate Array (FPGA)-based sensor node

Fused Smart Sensor Network for Multi-Axis Forward Kinematics Estimation in Industrial Robots

Flexible manipulator robots have a wide industrial application. Robot performance requires sensing its position and orientation adequately, known as forward kinematics. Commercially available, motion controllers use high-resolution optical encoders to sense the position of each joint which cannot detect some mechanical deformations that decrease the accuracy of the robot position and orientation. To overcome those problems, several sensor fusion methods have been proposed but at expenses of high-computational load, which avoids the online measurement of the joint’s angular position and the online forward kinematics estimation. The contribution of this work is to propose a fused smart sensor network to estimate the forward kinematics of an industrial robot. The developed smart processor uses Kalman filters to filter and to fuse the information of the sensor network. Two primary sensors are used: an optical encoder, and a 3-axis accelerometer. In order to obtain the position and orientation of each joint online a field-programmable gate array (FPGA) is used in the hardware implementation taking advantage of the parallel computation capabilities and reconfigurability of this device. With the aim of evaluating the smart sensor network performance, three real-operation-oriented paths are executed and monitored in a 6-degree of freedom robot

FPGA-based Fused Smart Sensor for Real-Time Plant-Transpiration Dynamic Estimation

Plant transpiration is considered one of the most important physiological functions because it constitutes the plants evolving adaptation to exchange moisture with a dry atmosphere which can dehydrate or eventually kill the plant. Due to the importance of transpiration, accurate measurement methods are required; therefore, a smart sensor that fuses five primary sensors is proposed which can measure air temperature, leaf temperature, air relative humidity, plant out relative humidity and ambient light. A field programmable gate array based unit is used to perform signal processing algorithms as average decimation and infinite impulse response filters to the primary sensor readings in order to reduce the signal noise and improve its quality. Once the primary sensor readings are filtered, transpiration dynamics such as: transpiration, stomatal conductance, leaf-air-temperature-difference and vapor pressure deficit are calculated in real time by the smart sensor. This permits the user to observe different primary and calculated measurements at the same time and the relationship between these which is very useful in precision agriculture in the detection of abnormal conditions. Finally, transpiration related stress conditions can be detected in real time because of the use of online processing and embedded communications capabilities

FPGA-Based Smart Sensor for Online Displacement Measurements Using a Heterodyne Interferometer

The measurement of small displacements on the nanometric scale demands metrological systems of high accuracy and precision. In this context, interferometer-based displacement measurements have become the main tools used for traceable dimensional metrology. The different industrial applications in which small displacement measurements are employed requires the use of online measurements, high speed processes, open architecture control systems, as well as good adaptability to specific process conditions. The main contribution of this work is the development of a smart sensor for large displacement measurement based on phase measurement which achieves high accuracy and resolution, designed to be used with a commercial heterodyne interferometer. The system is based on a low-cost Field Programmable Gate Array (FPGA) allowing the integration of several functions in a single portable device. This system is optimal for high speed applications where online measurement is needed and the reconfigurability feature allows the addition of different modules for error compensation, as might be required by a specific application

A New Methodology for Vibration Error Compensation of Optical Encoders

Optical encoders are sensors based on grating interference patterns. Tolerances inherent to the manufacturing process can induce errors in the position accuracy as the measurement signals stand apart from the ideal conditions. In case the encoder is working under vibrations, the oscillating movement of the scanning head is registered by the encoder system as a displacement, introducing an error into the counter to be added up to graduation, system and installation errors. Behavior improvement can be based on different techniques trying to compensate the error from measurement signals processing. In this work a new “ad hoc” methodology is presented to compensate the error of the encoder when is working under the influence of vibration. The methodology is based on fitting techniques to the Lissajous figure of the deteriorated measurement signals and the use of a look up table, giving as a result a compensation procedure in which a higher accuracy of the sensor is obtained

EMMNet: Sensor Networking for Electricity Meter Monitoring

Smart sensors are emerging as a promising technology for a large number of application domains. This paper presents a collection of requirements and guidelines that serve as a basis for a general smart sensor architecture to monitor electricity meters. It also presents an electricity meter monitoring network, named EMMNet, comprised of data collectors, data concentrators, hand-held devices, a centralized server, and clients. EMMNet provides long-distance communication capabilities, which make it suitable suitable for complex urban environments. In addition, the operational cost of EMMNet is low, compared with other existing remote meter monitoring systems based on GPRS. A new dynamic tree protocol based on the application requirements which can significantly improve the reliability of the network is also proposed. We are currently conducting tests on five networks and investigating network problems for further improvements. Evaluation results indicate that EMMNet enhances the efficiency and accuracy in the reading, recording, and calibration of electricity meters

A Vision-Based Quality Control Model for Manufacturing Systems

A thesis presented to the faculty of the College of Business and Technology at Morehead State University in partial fulfillment of the requirements for the Degree Master of Science by Alejandra Figueroa-Lopez on November 25, 2021

Design of Belief Propagation Based on FPGA for the Multistereo CAFADIS Camera

In this paper we describe a fast, specialized hardware implementation of the belief propagation algorithm for the CAFADIS camera, a new plenoptic sensor patented by the University of La Laguna. This camera captures the lightfield of the scene and can be used to find out at which depth each pixel is in focus. The algorithm has been designed for FPGA devices using VHDL. We propose a parallel and pipeline architecture to implement the algorithm without external memory. Although the BRAM resources of the device increase considerably, we can maintain real-time restrictions by using extremely high-performance signal processing capability through parallelism and by accessing several memories simultaneously. The quantifying results with 16 bit precision have shown that performances are really close to the original Matlab programmed algorithm

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