Distributed embedded system with internet GSM connectivity for intelligent e-monitoring of machine tools

Amer, Waseem. 2006. Distributed embedded system with internet GSM connectivity for intelligent e-monitoring of machine tools. PhD Thesis, Cardiff University.

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Abstract

Machining is one of the most important operations in many industrial environments. To prosper in today's competitive industrial world any machining system should be able to deliver the highest possible quality at the lowest possible costs, with very high reliability and flexibility. To fulfil these requirements the idea of e-Monitoring an industrial process was introduced by the Intelligent Process Monitoring and Management (IPMM) Centre at Cardiff University. It has considerable potential applications in industrial systems to not only monitor the health of the machines but also for data management and presentation for future decision making. The research presented in this thesis considers the evolution of two different low complexity signal analysis techniques which can be used for e-Monitoring the health of the cutters used in milling machine tools. The researched techniques are based in the time and frequency domains. The frequency domain analysis technique is based on the idea of using switched capacitor filters and microcontrollers to monitor the frequencies of interest in existing machine tool signals (spindle load and speed) thus avoiding the need for external sensors. The results of frequency domain analysis are used to assess the health of the cutter. The time domain analysis technique uses the same signals to analyse any variations within a tool rotation period and relate these to the health of the cutter. The results are integrated before final decision making which helps in reducing false alarms. The thesis goes on to logically describe the design and development of an on-line microcontroller based distributed intelligent e-Monitoring system for a milling machine tool model Kondia B500, using the proposed signal analysis techniques. Some additional features such as internet and GSM connectivity have also been added to the designed system. The designed system was interfaced to the machine tool and tested for its reliability which was found to be competitive with many other very expensive systems. The designed system can be fitted into a machine tool at the manufacturing stage or it could be interfaced to an existing machine tool for automatically detecting a tooth breakage.

Item Type:	Thesis (PhD)
Status:	Unpublished
Schools:	Engineering
Subjects:	T Technology > TJ Mechanical engineering and machinery
ISBN:	9781303205071
Funders:	Ministry of Science & Technology, Government of Pakistan
Date of First Compliant Deposit:	30 March 2016
Last Modified:	10 Oct 2017 15:29
URI:	https://orca.cardiff.ac.uk/id/eprint/56071

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