MAGNETIC ADD-ON SYSTEM WITH VIBRATION AND ACOUSTIC SENSING CAPABILITIES FOR TOOL CONDITION MONITORING
20190061086 ยท 2019-02-28
Assignee
- The Regents Of The University Of California (Oakland, unknown)
- INFINITE UPTIME, INC. (Fremont, CA, US)
Inventors
Cpc classification
B23Q17/12
PERFORMING OPERATIONS; TRANSPORTING
G01D11/30
PHYSICS
G10K11/004
PHYSICS
B23Q17/0971
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23Q17/09
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A magnetically attachable sensor assembly for sensing cutting tool operation. The magnetically attachable sensor assembly comprises an acoustic and vibration sensing apparatus, or sensor package, disposed in a housing having a portable, magnetic form factor for portability and easy clamping/attachment to a number of different surfaces.
Claims
1. An apparatus for monitoring operation of a machine tool while machining a workpiece, the apparatus comprising: (a) a magnetic sensor housing; (b) a sensor package disposed within a cavity of the magnetic sensor housing; (c) wherein the sensor housing is configured to releasably attach to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the magnetic housing; and (d) at least one vibration sensor and acoustic sensor disposed within said sensor package; (e) wherein said vibration sensor and acoustic sensor are configured for real-time monitoring of operational data of the machine tool.
2. The apparatus of claim 1, wherein the vibration sensor and acoustic sensor are disposed as a sensor package comprising: (i) a processor; (ii) an accelerometer coupled to the processor; (iii) an acoustic sensor coupled to the processor; and (iv) a memory storing instructions executable by the processor; (v) wherein said instructions, when executed by the processor, perform steps of acquiring vibration data and acoustic data from the accelerometer and acoustic sensor to perform real-time monitoring of the machine tool.
3. The apparatus of claim 2, the sensor package further comprising: (vi) a wireless transceiver connected to the processor, the wireless transceiver configured for transmitting the acquired vibration data and acoustic data to an external device.
4. The apparatus of claim 1: wherein the sensor housing comprises a cavity for securing the sensor package; and a magnet disposed at a surface of the housing configured to be positioned adjacent the machine surface.
5. The apparatus of claim 4, wherein the magnet is disposed within a pocket of said housing surface.
6. The apparatus of claim 5, wherein the housing comprises: a bottom case comprising said cavity and said pocket for housing the sensor package and magnet respectively; and an upper case configured to fit over the lower case to secure the sensor package within said cavity.
7. The apparatus of claim 2, wherein said instructions when executed by the processor, further perform steps comprising: acquiring vibration data from the accelerometer and storing the data in a buffer with timestamps; acquiring acoustic data from the acoustic sensor and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool.
8. The apparatus of claim 7, wherein said instructions when executed by the processor, further perform steps comprising: wirelessly sending the combined data in a single data package to an external data monitoring device.
9. The apparatus of claim 7, wherein said real-time monitoring comprises determining a condition of the machine tool from the combined data.
10. The apparatus of claim 7, wherein the accelerometer is sampled at a frequency to provide high resolution data of the vibrations of the workpiece due to cutting forces applied with the machine tool.
11. The apparatus of claim 7, wherein the acoustic sensor is sampled at a frequency to provide high frequency data of the workpiece due to cutting forces applied with the machine tool.
12. A method for monitoring operation of a machine tool, the method comprising: releasably coupling a sensor assembly to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the sensor assembly; acquiring vibration data and acoustic data from a location at said machine surface; and determining a condition of the machine tool as a function of the acquired accelerometer and acoustic data.
13. The method of claim 12, further comprising: wirelessly transmitting the acquired vibration data and acoustic data to an external device.
14. The method of claim 12, further comprising: acquiring vibration data from an accelerometer disposed within the sensor assembly and storing the data in a buffer with timestamps; acquiring acoustic data from an acoustic sensor within the sensor assembly and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool condition.
15. The method of claim 14, further comprising: wirelessly sending the combined data in a single data package to an external data monitoring device.
16. The method of claim 14, wherein acquiring vibration data comprises sampling the accelerometer at a frequency to provide high resolution data of the vibrations of the machine tool due to cutting forces applied with the machine tool.
17. The method of claim 14, wherein acquiring acoustic data comprises sampling the acoustic sensor at a frequency to provide high frequency data of the machine tool due to cutting forces applied with the machine tool.
18. An apparatus for monitoring operation of a machine tool while machining a workpiece, the apparatus comprising: (a) a magnetic sensor housing; (b) a sensor package disposed within a cavity of the magnetic sensor housing; (c) wherein the sensor housing is configured to releasably attach to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the magnetic housing; (d) wherein the sensor package comprises: (i) a processor; (ii) an accelerometer coupled to the processor; (iii) an acoustic sensor coupled to the processor; (iv) a memory storing instructions executable by the processor; and (v) wherein said instructions, when executed by the processor, perform steps of acquiring vibration data and acoustic data from the accelerometer and acoustic sensor to perform real-time monitoring of the machine tool.
19. The apparatus of claim 18, the sensor package further comprising: (vi) a wireless transceiver connected to the processor, the wireless transceiver configured for transmitting the acquired vibration data and acoustic data to an external device.
20. The apparatus of claim 18: wherein the sensor housing comprises a cavity for securing the sensor package; and a magnet disposed at a surface of the housing configured to be positioned adjacent the machine surface.
21. The apparatus of claim 20, wherein the magnet is disposed within a pocket of said housing surface.
22. The apparatus of claim 21, wherein the housing comprises: a bottom case comprising said cavity and said pocket for housing the sensor package and magnet respectively; and an upper case configured to fit over the lower case to secure the sensor package within said cavity.
23. The apparatus of claim 18, wherein said instructions when executed by the processor, further perform steps comprising: acquiring vibration data from the accelerometer and storing the data in a buffer with timestamps; acquiring acoustic data from the acoustic sensor and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool.
24. The apparatus of claim 23, wherein said real-time monitoring comprises determining a condition of the machine tool from the combined data.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0013] The technology described herein will be more fully understood by reference to the following drawings which are for illustrative purposes only:
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
DETAILED DESCRIPTION
[0020]
[0021] As will be explained in further detail below, sensor package 30 is configured for monitoring the operation of cutting/machining tools while using a vise (not shown) or other type of surface of machinery or equipment.
[0022]
[0023] As shown in
[0024] While the two-piece housing configuration of
[0025]
[0026] In one exemplary embodiment, the accelerometer 32 comprises a Bosch BMX055 digital 9-axis accelerometer, microphone 34 comprises an InvenSense ICS-43432 low-noise microphone with I.sup.2S digital output, MCU 36 comprises a Teensy 3.2 microcontroller, wireless transceiver 38 comprises a CC2541 Bluetooth communication module, and battery 42 comprises a 3.7V 170 mAh LiPo (Lithium Polymer) battery. It is appreciated that the above embodiment is for illustrative purposes only, and other component configurations are also contemplated.
[0027]
[0028] Referring now to sensing method 100 shown in the process flow diagram of
[0029] While sensor electronics assembly 30 is primarily configured to acquire vibration data and acoustic data, it is appreciated that other forms of sensors, e.g. thermometers, pressure sensors, strain gauges, etc., may also be implemented to acquire additional sensor data (e.g. temperature, pressure, strain, etc.).
[0030] In one embodiment, the accelerometer 32 communicates using the I.sup.2C protocol, whereas the microphone communicates using the I.sup.2S protocol. The wireless (Bluetooth) data communication is over serial data transfer. The output data may be further processed using via external device 40 via applications such as tool condition monitoring and process optimization. Appendix A provides an embodiment of instructions contained in application programming 48 that may be executable on a processor 36 (e.g. Teensy 3.2 microcontroller) to perform the functions shown in method 10 of
[0031] While the embodiments above are shown for use primarily with machine tools, it is appreciated that the technology is not restricted to machine tools alone, but can also be used in material handling equipment and other systems for real-time data collection.
[0032] Embodiments of the present technology may be described with reference to flowchart illustrations of methods and systems according to embodiments of the technology, and/or algorithms, formulae, or other computational depictions, which may also be implemented as computer program products. In this regard, each block or step of a flowchart, and combinations of blocks (and/or steps) in a flowchart, algorithm, formula, or computational depiction can be implemented by various means, such as hardware, firmware, and/or software including one or more computer program instructions embodied in computer-readable program code logic. As will be appreciated, any such computer program instructions may be loaded onto a computer, including without limitation a general purpose computer or special purpose computer, or other programmable processing apparatus to produce a machine, such that the computer program instructions which execute on the computer or other programmable processing apparatus create means for implementing the functions specified in the block(s) of the flowchart(s).
[0033] Accordingly, blocks of the flowcharts, algorithms, formulae, or computational depictions support combinations of means for performing the specified functions, combinations of steps for performing the specified functions, and computer program instructions, such as embodied in computer-readable program code logic means, for performing the specified functions. It will also be understood that each block of the flowchart illustrations, algorithms, formulae, or computational depictions and combinations thereof described herein, can be implemented by special purpose hardware-based computer systems which perform the specified functions or steps, or combinations of special purpose hardware and computer-readable program code logic means.
[0034] Furthermore, these computer program instructions, such as embodied in computer-readable program code logic, may also be stored in a computer-readable memory that can direct a computer or other programmable processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the block(s) of the flowchart(s). The computer program instructions may also be loaded onto a computer or other programmable processing apparatus to cause a series of operational steps to be performed on the computer or other programmable processing apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable processing apparatus provide steps for implementing the functions specified in the block(s) of the flowchart(s), algorithm(s), formula(e), or computational depiction(s).
[0035] It will further be appreciated that the terms programming or program executable as used herein refer to one or more instructions that can be executed by a processor to perform a function as described herein. The instructions can be embodied in software, in firmware, or in a combination of software and firmware. The instructions can be stored local to the device in non-transitory media, or can be stored remotely such as on a server, or all or a portion of the instructions can be stored locally and remotely. Instructions stored remotely can be downloaded (pushed) to the device by user initiation, or automatically based on one or more factors. It will further be appreciated that as used herein, that the terms processor, computer processor, central processing unit (CPU), and computer are used synonymously to denote a device capable of executing the instructions and communicating with input/output interfaces and/or peripheral devices.
[0036] From the description herein, it will be appreciated that that the present disclosure encompasses multiple embodiments which include, but are not limited to, the following:
[0037] 1. An apparatus for monitoring operation of a machine tool while machining a workpiece, the apparatus comprising: (a) a magnetic sensor housing; (b) a sensor package disposed within a cavity of the magnetic sensor housing; (c) wherein the sensor housing is configured to releasably attach to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the magnetic housing; and (d) at least one vibration sensor and acoustic sensor disposed within said sensor housing; (e) wherein said vibration sensor and acoustic sensor are configured for real-time monitoring of operational data of the machine tool.
[0038] 2. The apparatus of any preceding embodiment, wherein the vibration sensor and acoustic sensor are disposed as a sensor package comprising: (i) a processor; (ii) an accelerometer coupled to the processor; (iii) an acoustic sensor coupled to the processor; and (iv) a memory storing instructions executable by the processor; (v) wherein said instructions, when executed by the processor, perform steps of acquiring vibration data and acoustic data from the accelerometer and acoustic sensor to perform real-time monitoring of the machine tool.
[0039] 3. The apparatus of any preceding embodiment, the sensor package further comprising: (vi) a wireless transceiver connected to the processor, the wireless transceiver configured for transmitting the acquired vibration data and acoustic data to an external device.
[0040] 4. The apparatus of any preceding embodiment: wherein the sensor housing comprises a cavity for securing the sensor package; and a magnet disposed at a surface of the housing configured to be positioned adjacent the machine surface.
[0041] 5. The apparatus of any preceding embodiment, wherein the magnet is disposed within a pocket of said housing surface.
[0042] 6. The apparatus of any preceding embodiment, wherein the housing comprises: a bottom case comprising said cavity and said pocket for housing the sensor package and magnet respectively; and an upper case configured to fit over the lower case to secure the sensor package within said cavity.
[0043] 7. The apparatus of any preceding embodiment, wherein said instructions when executed by the processor, further perform steps comprising: acquiring vibration data from the accelerometer and storing the data in a buffer with timestamps; acquiring acoustic data from the acoustic sensor and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool.
[0044] 8. The apparatus of any preceding embodiment, wherein said instructions when executed by the processor, further perform steps comprising: wirelessly sending the combined data in a single data package to an external data monitoring device.
[0045] 9. The apparatus of any preceding embodiment, wherein said real-time monitoring comprises determining a condition of the machine tool from the combined data.
[0046] 10. The apparatus of any preceding embodiment, wherein the accelerometer is sampled at a frequency to provide high resolution data of the vibrations of the workpiece due to cutting forces applied with the machine tool.
[0047] 11. The apparatus of any preceding embodiment, wherein the acoustic sensor is sampled at a frequency to provide high frequency data of the workpiece due to cutting forces applied with the machine tool.
[0048] 12. A method for monitoring operation of a machine tool, the method comprising: releasably coupling a sensor assembly to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the sensor assembly; acquiring vibration data and acoustic data from a location at said machine surface; and determining a condition of the machine tool as a function of the acquired accelerometer and acoustic data.
[0049] 13. The method of any preceding embodiment, further comprising: wirelessly transmitting the acquired vibration data and acoustic data to an external device.
[0050] 14. The method of any preceding embodiment, further comprising: acquiring vibration data from an accelerometer disposed within the sensor assembly and storing the data in a buffer with timestamps; acquiring acoustic data from an acoustic sensor within the sensor assembly and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool condition.
[0051] 15. The method of any preceding embodiment, further comprising: wirelessly sending the combined data in a single data package to an external data monitoring device.
[0052] 16. The method of any preceding embodiment, wherein acquiring vibration data comprises sampling the accelerometer at a frequency to provide high resolution data of the vibrations of the machine tool due to cutting forces applied with the machine tool.
[0053] 17. The method of any preceding embodiment, wherein acquiring acoustic data comprises sampling the acoustic sensor at a frequency to provide high frequency data of the machine tool due to cutting forces applied with the machine tool.
[0054] 18. An apparatus for monitoring operation of a machine tool while machining a workpiece, the apparatus comprising: (a) a magnetic sensor housing; (b) a sensor package disposed within a cavity of the magnetic sensor housing; (c) wherein the sensor housing is configured to releasably attach to a machine surface associated with the machine tool via a magnetic attraction between the machine surface and the magnetic housing; (d) wherein the sensor package comprises: (i) a processor; (ii) an accelerometer coupled to the processor; (iii) an acoustic sensor coupled to the processor; (iv) a memory storing instructions executable by the processor; and (v) wherein said instructions, when executed by the processor, perform steps of acquiring vibration data and acoustic data from the accelerometer and acoustic sensor to perform real-time monitoring of the machine tool.
[0055] 19. The apparatus of any preceding embodiment, the sensor package further comprising: (vi) a wireless transceiver connected to the processor, the wireless transceiver configured for transmitting the acquired vibration data and acoustic data to an external device.
[0056] 20. The apparatus of any preceding embodiment: wherein the sensor housing comprises a cavity for securing the sensor package; and a magnet disposed at a surface of the housing configured to be positioned adjacent the machine surface.
[0057] 21. The apparatus of any preceding embodiment, wherein the magnet is disposed within a pocket of said housing surface.
[0058] 22. The apparatus any preceding embodiment, wherein the housing comprises: a bottom case comprising said cavity and said pocket for housing the sensor package and magnet respectively; and an upper case configured to fit over the lower case to secure the sensor package within said cavity.
[0059] 23. The apparatus of any preceding embodiment, wherein said instructions when executed by the processor, further perform steps comprising: acquiring vibration data from the accelerometer and storing the data in a buffer with timestamps; acquiring acoustic data from the acoustic sensor and storing the data in a buffer with timestamps; and combining the collected vibration and acoustic data for real-time monitoring of the machine tool.
[0060] 24. The apparatus of any preceding embodiment, wherein said real-time monitoring comprises determining a condition of the machine tool from the combined data.
[0061] 25. An apparatus, comprising: a magnetic add-on device; and vibration and acoustic sensors contained in the said device; said sensors configured for real-time monitoring of operational data from a vise used in a manufacturing machine tool.
[0062] 26. The apparatus of any preceding embodiment, further comprising a wireless data communications interface connected to said sensors for transmitting data from said sensors to a remote location.
[0063] 27. An apparatus, comprising: a housing with an embedded magnet; and vibration and acoustic sensors embedded in the housing; said sensors configured for real-time monitoring of operational data from such a portable add-on device used in a manufacturing machine tool.
[0064] 28. The apparatus of any preceding embodiment, further comprising a wireless data communications interface connected to said sensors for transmitting data from said sensors to a remote location.
[0065] 29. An apparatus for acoustic and vibration monitoring of a cutting tool while using a retrofit, the apparatus comprising: (a) a magnetic add-on device; (b) a sensor housing within the device body; and (c) a sensor system fitted within the sensor housing; (d) the sensor system comprising: (i) a signal processing unit; (ii) an accelerometer connected to the signal processing unit; (iii) an acoustic sensor connected to the signal processing unit; (iv) a wireless communications device connected to the signal processing unit; (v) the signal processing unit including a processor and a memory storing instructions executable by the processor, wherein said instructions, when executed, perform steps comprising: acquiring acoustic data from the accelerometer and storing the data in a buffer; acquiring vibration data from the acoustic sensor and storing the data in a buffer; and combining the collected vibration and acoustic data and sending the combined data wirelessly in a single data package through the wireless communications device, or using a wire, to a data monitoring system.
[0066] 30. An apparatus for acoustic and vibration monitoring of a cutting tool, the apparatus comprising: (a) a 2-piece press-fitted sensor housing; (b) a magnet fitted within the housing; and (c) a sensor system fitted within the sensor housing; (d) the sensor system comprising: (i) a signal processing unit; (ii) an inertial measurement unit (IMU) connected to the signal processing unit; (iii) an acoustic sensor connected to the signal processing unit; (iv) a wireless communications device connected to the signal processing unit; (v) the signal processing unit including a processor and a memory storing instructions executable by the processor, wherein said instructions, when executed, perform steps comprising: acquiring acoustic data from the accelerometer and storing the data in a serial buffer; acquiring vibration data from the acoustic sensor and storing the data in a buffer; and combining the collected vibration and acoustic data and sending the combined data wirelessly in a single data package through the wireless communications device, or through a USB micro B cable, to a data monitoring system.
[0067] Although the description herein contains many details, these should not be construed as limiting the scope of the disclosure but as merely providing illustrations of some of the presently preferred embodiments. Therefore, it will be appreciated that the scope of the disclosure fully encompasses other embodiments which may become obvious to those skilled in the art.
[0068] In the claims, reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. All structural, chemical, and functional equivalents to the elements of the disclosed embodiments that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed as a means plus function element unless the element is expressly recited using the phrase means for. No claim element herein is to be construed as a step plus function element unless the element is expressly recited using the phrase step for.