An FFT-based high-speed spindle monitoring system for analyzing vibrations
01 Dec 2017-pp 1-4
TL;DR: A Fast Fourier Transform (FFT)-based monitoring system which is applied to measure, monitor, and analyze the vibrations of the high-speed spindle to recognize normal/abnormal vibrations is proposed.
Abstract: This paper proposes a Fast Fourier Transform (FFT)-based monitoring system which is applied to measure, monitor, and analyze the vibrations of the high-speed spindle. The piezoelectric sensor based accelerometer can real-time measure the signals of the vibrations when the high-speed spindle is vibrated. These signals of the vibrations are sent to a cloud-based platform via wireless communication techniques. The meaningful characteristic of vibrations are captured by the FFT technique. Moreover, a database is built as sample patterns (all kinds of damage and normal operations), according to these related characteristic. Therefore, it can assist us to recognize normal/abnormal vibrations. The behaviors of abnormal vibration occurred in the high-speed spindle can also be predicted for early maintenance.
Citations
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TL;DR: A vibration measurement method based on multiple-input multiple-output imaging radar system, which can achieve high azimuth resolution and adopts multiple signal classification least-squares estimation method to estimate the vibrating frequency and amplitude.
Abstract: Measuring the vibrating states of an artificial structure is an important approach to monitor the stability of the structure. However, the existing radar vibration measurement methods do not have enough azimuth resolution for measuring the vibrations in a relatively large scene, which contains multiple buildings or a large building. For such application scene, this paper proposes a vibration measurement method based on multiple-input multiple-output imaging radar system, which can achieve high azimuth resolution. Features of the proposed method are threefold: first of all, by utilizing the ability of quickly acquiring imaging data, the proposed method can achieve vibration measurement for the entire area simultaneously; second, in order to detect the positions of vibrating objects and decrease the time of vibration parameter estimation part, this paper proposes vibration similarity index to quantify the similarity between the detected signal and ideal vibration signal; at last, due to the limitations of the hardware performance, this paper adopts multiple signal classification least-squares estimation method to estimate the vibrating frequency and amplitude. To evaluate the performance of the proposed method, ideal point target simulation and vibrating calibrator experiment have been conducted, and the results show that the positions and the vibrating parameters of the vibrating objects fit well with the reference values. In addition, car experiment and bridge experiment have been carried out to verify the ability of the proposed method to measure the vibration of real artificial structures, which cannot be seen as point targets.
16 citations
Cites methods from "An FFT-based high-speed spindle mon..."
...Generally, vibrating frequency is estimated using periodogram method [27], and vibrating amplitude is estimated using harmonic ratio method [7], [28], [29]....
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01 Jan 2019
TL;DR: In this paper, triple axis accelerometer ADXL335 is used for acceleration measurement, cost effective ARM M4 processor TM4C123GXL is used as processing unit and low power Zigbee transceiver is used to transfer the vibration data.
Abstract: Vibration in electrical and mechanical systems is an important parameter which is related to the systems health, stability and efficiency. In practical condition, the system is distributed and most of the time unreachable during their operating time. In this paper, triple axis wireless vibration monitoring system for distributed system is described. The system also includes development of real time graphical user interface with MATLAB. Here triple axis accelerometer ADXL335 is used for acceleration measurement , cost effective ARM M4 processor TM4C123GXL is used as processing unit and low power Zigbee transceiver is used to transfer the vibration data. To prevent data tapping, the data is encrypted by Advanced Encryption Standard (AES) algorithm in sending side and then decrypted in receiver end. The overall latency of the system is also measured. The received signal strength based performance analysis is also done where the RSSI value is approximately -43dBm at 587.94m distance. The system is tested for vibration measurement of a single phase induction motor.
8 citations
Cites background from "An FFT-based high-speed spindle mon..."
...FFT based vibration monitoring system is also developed in [11]....
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TL;DR: In this article , a combination of multiple sensors including three-axis accelerometer and acoustic emission (AE) sensor and driver current detector of the spindle, is used to collect respective data of the milling cutter during machining process of the CNC machines.
Abstract: ABSTRACT Status of the cutting tool has a great impact on the quality of the final product during the machining processes. However, the cutting tool condition monitoring (TCM) system mostly stays at the stage of research and development in the literature. In this research task, a combination of multiple sensors including three-axis accelerometer and acoustic emission (AE) sensor and driver current detector of the spindle, is used to collect respective data of the milling cutter during machining process of the CNC machines. The information is used indirectly to justify the tool wear level. During the machining process, two types of the cutter with different materials are considered with cutting paths classified into three categories: straight cutting path, square cutting path, and circle cutting path. We also propose a signal feature extraction method combined with an ANN for the TCM system. It can be used to perceive the difference between tool materials and wear level in three standard types of cutting path. Finally, online analysis supported by the TCM system is developed to show the identification accuracy of tool wear.
1 citations
TL;DR: In this article , a complete 3D integrated sensing system intended for practical applications was presented on a printed circuit board (PCB) board, starting with lead-free piezoelectric films deposited using an RF sputtering system, an MEMS structure design/simulation, device fabrication, and a signal processing chip design, including charge-to-voltage transformation, signal amplification, 60-Hz noise rejection, and low-power RF wireless transmission chip for remote monitoring.
Abstract: In this article, a complete 3-D integrated sensing system intended for practical applications was presented on a printed circuit board (PCB) board, starting with lead-free piezoelectric films deposited using an RF sputtering system, an MEMS structure design/simulation, device fabrication, and a signal processing chip design, including charge- to-voltage transformation, signal amplification, 60-Hz noise rejection, and low-power RF wireless transmission chip for remote monitoring. Both the signal processing chips and the RF wireless transmitter chips were manufactured using the Taiwan Semiconductor Manufacturing Company (TSMC) CMOS process. The piezoelectric coefficient d33 was measured as 27.21 pm/V of the proposed ZnO:Li doped Mg (MLZO) films. To meet the frequency specifications of industrial applications, the ring-structure devices with a 7730-Hz resonance frequency were designed using ANSYS simulation software. There was only a 0.39% deviation compared to the simulation results with the actual experimental data. The measurement results of the proposed system showed that the acceleration detection range was approximately 137 mV/ $\text{g}_{\mathrm {(p-p)}}$ . The voltage-controlled oscillator (VCO) adopted in the wireless transmitter chip had a four-leaf clover structure inductor with two symmetrical axes resulting in better suppression of magnetic field radiation. Finally, this system was applied to industrial spindles, and the normal and abnormal operation information of spindles was successfully and wirelessly monitored.
TL;DR: In this article , a complete 3D integrated sensing system intended for practical applications was presented on a printed circuit board (PCB) board, starting with lead-free piezoelectric films deposited using an RF sputtering system, an MEMS structure design/simulation, device fabrication, and a signal processing chip design, including charge-to-voltage transformation, signal amplification, 60-Hz noise rejection, and low-power RF wireless transmission chip for remote monitoring.
Abstract: In this article, a complete 3-D integrated sensing system intended for practical applications was presented on a printed circuit board (PCB) board, starting with lead-free piezoelectric films deposited using an RF sputtering system, an MEMS structure design/simulation, device fabrication, and a signal processing chip design, including charge- to-voltage transformation, signal amplification, 60-Hz noise rejection, and low-power RF wireless transmission chip for remote monitoring. Both the signal processing chips and the RF wireless transmitter chips were manufactured using the Taiwan Semiconductor Manufacturing Company (TSMC) CMOS process. The piezoelectric coefficient d33 was measured as 27.21 pm/V of the proposed ZnO:Li doped Mg (MLZO) films. To meet the frequency specifications of industrial applications, the ring-structure devices with a 7730-Hz resonance frequency were designed using ANSYS simulation software. There was only a 0.39% deviation compared to the simulation results with the actual experimental data. The measurement results of the proposed system showed that the acceleration detection range was approximately 137 mV/ $\text{g}_{\mathrm {(p-p)}}$ . The voltage-controlled oscillator (VCO) adopted in the wireless transmitter chip had a four-leaf clover structure inductor with two symmetrical axes resulting in better suppression of magnetic field radiation. Finally, this system was applied to industrial spindles, and the normal and abnormal operation information of spindles was successfully and wirelessly monitored.
References
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TL;DR: In this article, the optimization of turning operations based on the Taguchi method with multiple performance characteristics is proposed, and the orthogonal array, multi-response signal-to-noise ratio, and analysis of variance are employed to study the performance characteristics in turning operations.
237 citations
Additional excerpts
...[5] adopted Taguchi-based experimental planning method....
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TL;DR: In this article, a system developed for on-line vibration control on a turning lathe is presented, where relative vibration between the workpiece and the cutting tool is sensed with the help of a bifurcated bunch of optical fibres which is then phase shifted, amplified and fed back to a specially designed piezoelectric vibrator supporting the tool.
Abstract: This paper presents a system developed for on-line vibration control on a turning lathe. Relative vibration between the workpiece and the cutting tool is sensed with the help of a bifurcated bunch of optical fibres which is then phase shifted, amplified and fed back to a specially designed piezoelectric vibrator supporting the tool. Whenever a vibration occurs, leading the machine tool-cutting process system to instability, the close-dloop feedback contour, with the help of the vibrator-exciter, generates an equal and opposite force to stabilize the vibration. Results obtained by mathematical modelling and experimental investigations indicate a significant improvement in the dynamic characteristics of the machine tool resulting in considerably higher productivity, accuracy and finish.
44 citations
"An FFT-based high-speed spindle mon..." refers methods in this paper
...[3] proposed a hybrid methodology, which was combined the knife and the piezoelectric actuator to measure the relative motion of the workpiece by the photoelectric sensor....
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01 Jan 2017
TL;DR: In this article, condition-based maintenance (CBM) practices are used to plan for maintenance action based on the condition of the machines and to prevent failures by solving the problems in advance as well as controlling the accuracy of the machining operations.
Abstract: Machining systems (i.e., machine tools, cutting processes and their interaction) cannot produce accurate parts if performance degradation due to wear in their subsystems (e.g., feed-drive systems and spindle units) is not identified, monitored and controlled. Appropriate maintenance actions delay the possible deterioration and minimize/avoids the machining system stoppage time that leads to lower productivity and higher production cost. Moreover, measuring and monitoring machine tool condition has become increasingly important due to the introduction of agile production, increased accuracy requirements for products and customers' requirements for quality assurance. Condition Based Maintenance (CBM) practices, such as vibration monitoring of machine tool spindle units, are therefore becoming a very attractive, but still challenging, method for companies operating high-value machines and components. CBM is being used to plan for maintenance action based on the condition of the machines and to prevent failures by solving the problems in advance as well as controlling the accuracy of the machining operations. By increasing the knowledge in this area, companies can save money through fewer acute breakdowns, reduction in inventory cost, reduction in repair times, and an increase in the robustness of the manufacturing processes leading to more predictable manufacturing. Hence, the CBM of machine tools ensures the basic conditions to deliver the right ability or capability of the right machine at the right time. One of the most common problems of rotating equipment such as spindles is the bearing condition (due to wear of the bearings). Failure of the bearings can cause major damage in a spindle. Vibration analysis is able to diagnose bearing failures by measuring the overall vibration of a spindle or, more precisely, by frequency analysis. Several factors should be taken into consideration to perform vibration monitoring on a machine tool's spindle. Some of these factors are as follows: the sensor type/sensitivity, number of sensors to be installed on the spindle in different directions, positioning of the vibration accelerometers, frequency range to be measured, resonance frequency, spindle rotational speed during the measurements,
33 citations
"An FFT-based high-speed spindle mon..." refers methods in this paper
...*Corresponding author: Prof. Wan-Jung Chang 978-1-5090-6526-4/17/$31.00 ©2017 Crown based MCU (STM32F429 is adopted), two BLE modules, a BLE bridge, a gateway....
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...In this paper, a built-in 12-bit ADC ARM-based MCU, STM32F429 [8], is adopted to process related digital signals (measured data) for matching the corresponding original ana- 978-1-5090-6526-4/17/$31.00 ©2017 Crown logue value of the vibrations....
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...In this paper, a built-in 12-bit ADC ARM-based MCU, STM32F429 [8], is adopted to process related digital signals (measured data) for matching the corresponding original ana2017 Eleventh International Conference on Sensing Technology (ICST)...
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05 Apr 2017
TL;DR: In this paper, a gap analysis of the gap between the requirements supported by the current automotive manufacturing execution systems (MES) and the requirements proposed by industrial standards from the International Societyof Automation (ISA) such as, ISA-95, ISSA-88 over which the Industry 4.0 is being built on is presented.
Abstract: The dawn of the fourth industrial revolution, Industry4.0 has created great enthusiasm among companies andresearchers by giving them an opportunity to pave the pathtowards the vision of a connected smart factory ecosystem. However, in context of automotive industry there is an evident gapbetween the requirements supported by the current automotivemanufacturing execution systems (MES) and the requirementsproposed by industrial standards from the International Societyof Automation (ISA) such as, ISA-95, ISA-88 over which theIndustry 4.0 is being built on. In this paper, we bridge this gapby following a model-based requirements engineering approachalong with a gap analysis process. Our work is mainly dividedinto three phases, (i) automotive MES tool selection phase, (ii) requirementsmodeling phase, (iii) and gap analysis phase based onthe modeled requirements. During the MES tool selection phase, we used known reliable sources such as, MES product surveyreports, white papers that provide in-depth and comprehensiveinformation about various comparison criteria and tool vendorslist for the current MES landscape. During the requirementmodeling phase, we specified requirements derived from theneeds of ISA-95 and ISA-88 industrial standards using the generalpurpose Systems Modeling Language (SysML). During thegap analysis phase, we find the misalignment between standardrequirements and the compliance of the existing software toolsto those standards.
29 citations
Posted Content•
TL;DR: This paper bridges the gap between requirements supported by the current automotive manufacturing execution systems (MES) and the requirements proposed by industrial standards from the International Society of Automation (ISA) such as, ISA-95,ISA-88 over which the Industry 4.0 is being built on.
Abstract: The dawn of the fourth industrial revolution, Industry 4.0 has created great enthusiasm among companies and researchers by giving them an opportunity to pave the path towards the vision of a connected smart factory ecosystem. However, in context of automotive industry there is an evident gap between the requirements supported by the current automotive manufacturing execution systems (MES) and the requirements proposed by industrial standards from the International Society of Automation (ISA) such as, ISA-95, ISA-88 over which the Industry 4.0 is being built on. In this paper, we bridge this gap by following a model-based requirements engineering approach along with a gap analysis process. Our work is mainly divided into three phases, (i) automotive MES tool selection phase, (ii) requirements modeling phase, (iii) and gap analysis phase based on the modeled requirements. During the MES tool selection phase, we used known reliable sources such as, MES product survey reports, white papers that provide in-depth and comprehensive information about various comparison criteria and tool vendors list for the current MES landscape. During the requirement modeling phase, we specified requirements derived from the needs of ISA-95 and ISA-88 industrial standards using the general purpose Systems Modeling Language (SysML). During the gap analysis phase, we find the misalignment between standard requirements and the compliance of the existing software tools to those standards.
28 citations
"An FFT-based high-speed spindle mon..." refers background in this paper
...From the past to the present, the machinery manufacturing industry has been recognized as a major pillar of a nation’s economic lifeline [1]....
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