The design of an effective sensor fusion model for condition monitoring systems of turning processes

Abstract

High energy price and the increasing requirements of quality and low cost of products have created an urgent need to implement new technologies in current automated manufacturing environments. Condition monitoring systems of manufacturing processes have been recognised in recent years as one of the essential technologies that provide the competitive advantage in many manufacturing environments. This research aims to develop an effective sensor fusion model for turning processes for the detection of tool wear. Multi-sensors combined with a novelty detection algorithm and Learning Vector Quantisation (LVQ) neural networks are used in this research to detect tool wear and provide diagnostic and prognostic information. A novel approach, termed ASPST, (Automated Sensor and Signal Processing Selection System for Turning) is used to select the most appropriate sensors and signal processing methods. The aim is to reduce the number of sensors needed in the overall system and reduce the cost. The ASPST approach is based on simplifying complex sensory signals into a group of Sensory Characteristic Features (SCFs) and evaluating the sensitivity of these SCFs in detecting tool wear. A wide range of sensory signals (cutting forces, strain, acceleration, acoustic emission and sound) and signal processing methods are also implemented to verify the capability of the approach. A cost reduction method is also implemented based on eliminating the least utilised sensor in an attempt to reduce the overall cost of the system without sacrificing the capability of the condition monitoring system. The experimental results prove that the suggested approach provides a responsive and effective solution in monitoring tool wear in turning with reduced time and cost