Automatic Multiple Sensor Data Acquisition System in a Real-time Production Environment

This paper presents a multiple sensor automatic data acquisition system deployed on a CNC turning center in a real- time production environment at Schivo Precision, Waterford, Ireland. The machine has been fitted with a variety of sensors measuring acoustic emission, cutting force & vibration installed at the turret of the machine, coupled with an automatic image acquisition system monitoring the wear on the tools in real time after each operation. The combination of sensors and data acquisition is novel in that it brings together all the currently popular sensoring techniques in the field of tool condition monitoring and tests the validity of these techniques in a live production environment. The sensor data acquisition and optical tool wear measurements are controlled by a computer automatically with no intervention from the machine tool operator in normal production on a variety of component geometries, materials and cutting inserts. All the acquired data is available on-line for the research partners in the various countries. Independent operator feedback on the performance of the process in terms of both product dimensional stability and machined surface stability is used for evaluation of the acquired data applicability for tool condition monitoring.