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INTEGRATION OF FIBER OPTIC SENSORS FOR THE MONITORING OF ADVANCED MACHINE-TOOLS

Objective


Force sensor based on TBTF technology.
It has been developed until a precompetitive stage. First experiments have been realized in the laboratory, but experiments are needed in industrial application. Its small size makes it competitive against traditional piezoelectric sensors.

Fibre optic vibration sensor.
Simple, robust and highly accurate. Industrial experimentation is still needed to confirm the suitability of the sensor.

Analogue probe (BP2).
The BP2 was primarily designed for high precision measurement on coordinate measuring machines. Analogue probes are generally acknowledged to provide higher accuracy than the more commonly used touch-trigger probes. However, current commercial analogue probes are expensive and bulky compared with touch-trigger types.
It has been presented to potential users at machine-tool exhibition fair.

3D High resolution temperature data logger and alarm system (TEMPULOG).
Primarily designed to interface optic fibre temperature sensors, easily adapted to PT100, and converted in a general purpose temperature data logging and alarm system. It is mainly focused for process industry, and is being successfully marketed into the food processing industry.
More than 100 systems sold already in EU.

DSP based system for data acquisition and datalogging (LOGSTATION).
DSP based general purpose system providing fast data acquisition and control system with on board real time data processing. All system parametres such as gain, offset control, sampling rate and calibration routines are fully programmable from the host computer.
Already being commercialized and sold in the UK.

Thermal deformations compensation software module.
This module is designed to be introduced as option into milling machines (with at least 4 PT100 or similar temperature sensors). It runs under Windows and offers user friendly interface for the different features. It reduces the machine deformations due to thermal behaviour.
It is currently being offered to machine tool end users. Retrofitting is also available.

Predictive maintenance software module.
Windows based user friendly software module for predictive maintenance applications. It consists of an interface between the signals from the sensors in the machine and the operators, who may receive and analize the causes.
The objective is to integrate intrinsic fiber optic sensors with advanced signal and data processing capabilities to enable high performance operation of machine-tools. Traditional methods of process control involve post process measurement and statistical analysis prior to feedback to the process parameters. The delay in this form of feedback leads to slow process control adjustments and consequential quality loses.

Results of this project will improve overall machine-tool performance by means of the in-process monitoring of machine condition and production quality. To fulfill these objectives, the following tasks will be performed :

1. Sensor integration into the machine-tool
2. Development of interfaces between the system components. Including the signal data processing.
3. Integrated sensors module data analysis. (multivariable correlations, magnitudes mutual influences)
4. Integration of machine-sensor system into quality network.
5. Development of performance monitoring system.
6. Integration and test of the developed modules in the prototye.

The techniques will be applied to the selected machine-tool sector but can be regardered as generic in that the methodology and data processing techniques will apply to a wide range of manufacturing processes. Machine-tool accuracy improvement of 200% is expected, and global maintenance cost reduction of 65%.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

TRIMEK S. A.
Address
Legutianoko Industrialdea Pol. Ind. Gojain
01170 Vitoria
Spain

Participants (7)

3D Digital Design and Development Ltd
United Kingdom
Address
Interface House, Chelmsford R.
N14 4JN London
Brunel University
United Kingdom
Address
Kingston Lane
UB8 3PH Uxbridge
CARSA SA
Spain
Address
Avenida De Zugazarte 8-1Ø
48930 Guecho (Vizcaya)
ISOTEST LTD
Italy
Address
Via Roma 8
10090 Reano
Osu SpA
Italy
Address
Strada Comunale 29 Borgaretto
10043 Orbassano Torino
TEKNIKER
Spain
Address
Avda. Otaola 20
20600 Eibar
ZAYER SA
Spain
Address
Carretera De Vergara 7
01013 Vitoria