This paper introduces a new method for tool condition monitoring in transfer machining stations. The new method is developed based on a combination of wavelet transform, signal reconstruction, and the probability of threshold crossing. It consists of two parts: training and decision making. Training is aimed at determining the alarm threshold and it is done in six steps: (1) Calculate the wavelet packet transform of the sensor signals (spindle motor current) obtained from normal tool conditions. (2) Select feature wavelet packets that represent the principal components of the signals. (3) Reconstruct the signals from the feature wavelet packets (this removes the unwanted noises). (4) Calculate the statistics of the reconstructed signals. (5) Calculate the alarm thresholds based on the statistics of the reconstructed signals, and (6) Calculate the probability of the threshold crossing (the number of threshold crossing conforms a Poisson distribution). The decision making is done in two steps: (1) Check the threshold crossing, and (2) Calculate the number of threshold crossing to determine whether an alarm shall be given. As demonstrated using a practical example from a drilling transfer station, the new method is effective with a success rate over 90 percent. Also, it is fast (the monitoring decision can be done in milliseconds) and cost-effective (the implementation cost shall be less than $500).
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A New Method for Real-Time Tool Condition Monitoring in Transfer Machining Stations1
Ya Wu,
Ya Wu
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
22
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Philippe Escande,
Philippe Escande
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
33
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R. Du
R. Du
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
Search for other works by this author on:
Ya Wu
22
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
Philippe Escande
33
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
R. Du
Dept. of Industrial Engineering, University of Miami, Miami, FL 33124
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received Nov. 1997; revised Feb. 2000. Associate Editor: S. G. Kapoor.
J. Manuf. Sci. Eng. May 2001, 123(2): 339-347 (9 pages)
Published Online: February 1, 2000
Article history
Received:
November 1, 1997
Revised:
February 1, 2000
Citation
Wu, Y., Escande, P., and Du, R. (February 1, 2000). "A New Method for Real-Time Tool Condition Monitoring in Transfer Machining Stations." ASME. J. Manuf. Sci. Eng. May 2001; 123(2): 339–347. https://doi.org/10.1115/1.1334859
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