MTConnect_Challenge_Siegel_v3.doc.docVIP

Program Name: MTConnect Challenge Title of Idea: A MTConnect Enabled Platform for Machine Tool Component Health Prognosis and Tool Condition Monitoring Respondent Name: David Siegel Organization: NSF I/UCRC Center for Intelligent Maintenance Systems – University of Cincinnati Phone Number: 513-290-8163 Email address: siegeldn@mail.uc.edu Date of Proposal: May 31, 2013 Section 1: Abstract The maintenance cost and losses in productivity with unplanned downtime for machine tool components such as spindle bearings and ball screws could be reduced if one could proactively take action prior to failure. In addition, cutting tools and inserts are expensive to replace when they are still in good condition, but replacing the tools too late can be costly due to scrap and re-work. The proposed health monitoring application will use MTConnect to extract controller data and pattern recognition algorithms to assess the health condition of the spindle and machine tool axes. The health assessment approach is based on running a routine program each shift in which the most recent data patterns are compared to the baseline data patterns. An online tool condition monitoring module is also proposed and uses controller data such as the spindle motor current, with other add on sensors (vibration, acoustic emission) to accurately estimate and predict tool wear. By collecting data using the MTConnect standard, the platform aims to have widespread adoption in factories. In addition, with the added transparency of the machine tool health information, one can take proactive actions before significant downtime or productivity losses occur. Section II: Proposed Idea The era of the “fail and fix” maintenance policy for machine tools is over and has been replaced by the “predict and prevent” strategy that is being enabled by the ease of data collection using the MTConnect standard and the maturation of health monitoring algorithms. In order to achieve this widespread factory adoptio