A case study: monitoring and inspection based on IoT for milling process

Abstract

Cyber-Physical Machine Tools (CPMT) is currently recognized as a new generation of machine tools that align with Industry 4.0 needs as a smart, well-connected, advanced accessibility and more adaptive and autonomous solution. It can be achieved through standardized design method and communication protocols. This article presents a case study on monitoring and inspection based on Internet of Things (IoT) for milling process toward CPMT. The proposed solution is capable to work in both G-code and Standard for Product Data Exchange Compliant with Numerical Control (STEP-NC)-based controller. The proposed case study demonstrated the controller’s capabilities. An IoT-based monitoring architecture was implemented for milling process monitoring. This approach is suitable for both standard. The interpreted machining information will be utilized to enable the machining parameter update and enable monitoring and machining integration and finally extendable for control activity. The monitoring and inspection approaches can achieve high accuracy of machining process condition detection and enable measurement of machined parts to fulfil CPMT needs and I4.0. The case study validated that the developed monitoring approach performed well and was highly sensitive to any changes during the machining process, specifically on the tool condition. While in the inspection approach, the reliability of the machined model was 99.97%. Based on the results of both the approaches, it is confirmed that both tasks can be designed and support digital factory and other manufacturing process stages in the future such as preventive maintenance, inspecting, sizing, assembling and others.