FIELD

The present disclosure relates to the field of a performance monitoring of CNC machines.

BACKGROUND The background information herein below relates to the present disclosure but is not necessarily prior art.

Generally, tools and sub-systems of a computerized numerical control (CNC) machine are subjected to a variety of factors such as heat, force, friction, wear, thereby making the working of the CNC system complicated and susceptible to failure. As a result, a lot of time and effort are spent to diagnose and understand the real reason of failure of the CNC system. This eventually leads to economic losses since the production is delayed. Further the reliability and efficiency of the CNC system decreases. Therefore, fault diagnosis and maintenance are important aspects considered during the functioning of a CNC system.

There is therefore felt a need for a system for performance monitoring of a CNC machines by performing continuous real-time diagnosis and maintenance of the sub-systems of CNC machines.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows: One object of the present disclosure is to provide a performance monitoring system of CNC machines.

Yet another object of the present disclosure is to provide a system that predicts the failure of the components of the CNC machine.

Still another object of the present disclosure is to provide a system that decreases the failure rate of a CNC machines. Another object of the present disclosure is to provide a system that eliminates economic losses due to failure.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure. SUMMARY

The present disclosure envisages a performance monitoring system of a CNC machines. The performance monitoring system comprises a plurality of sensors, a control unit and a server. The plurality of sensors are configured to periodically sense a plurality of parameters. The sensors are further configured to generate a plurality of sensed values corresponding to the parameters. The control unit is configured to cooperate with the sensors, to receive the sensed value, compare the sensed values with corresponding pre-determined threshold values and generate at least one alert based on the comparison and transmit to a server. The server is configured to receive the alerts and further configured to log the alerts and transmit to a remotely located user device associated with a user. In an embodiment, the sensors are selected from a group consisting of optical sensors, vibration sensors, sound sensors, pressure sensor, flow sensors, electromagnetic sensors, current sensors, voltage sensors and combination thereof.

In another embodiment the control unit includes a repository, a crawler and extractor, and a comparator. The repository is configured to store a look up table having a list of the parameters, first threshold values and a second threshold value corresponding to each of said parameters.

The crawler and extractor is configured to cooperate with the repository to crawl through the look up table to extract the first and second threshold values corresponding to each of said sensed parameters. The comparator is configured to cooperate with the crawler and extractor to compare the sensed values with the extracted first and second threshold values and to generate a first comparison value and a second comparison value.

In an embodiment, the control unit includes an alert generation module. The alert generation module is configured to generate the alerts based on the comparison values. The alert generation module generates a first alert based on the first comparison value and transmit the first alert to the server and a second alert based on the second comparison value and transmit the second alert to the server.

In another embodiment, the control unit is configured to generate a stop signal on generation of the second alert, and is further configured to transmit the stop signal to the CNC machine to stop the functioning.

In yet another embodiment, a first communication module is configured to communicate between the server and the sensors, a second communication module is configured to communicate between the server and the user device and a third communication module is configured to communicate between the server and the control unit.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

A performance monitoring system of the present disclosure will now be described with the help of the accompanying drawing, in which:

Figure 1 illustrates a block diagram of a performance monitoring system of a CNC machine. LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING

100 - System

102 - Sensors

104 - Control unit 106 - Repository

108 - Crawler and extractor

110 - Comparator

112 - Alert generation module

114 - CNC machine 116 - User associated device 118a - First communication module

118b - Second communication module 118c - Third communication module 120 - Server DETAILED DESCRIPTION

Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail. The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms“a”,“an” and“the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms“comprises”,“comprising”,“including” and“having” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

When an element is referred to as being“mounted on”,“engaged to”,“connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term“and/or” includes any and all combinations of one or more of the associated listed elements. The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.

Terms such as“inner”,“outer”,“beneath”,“below”,“lower ”,“above”,“upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.

The present disclosure envisages a performance monitoring system 100 (hereinafter referred as“system 100”) of a CNC machine 114, the system 100 comprises a plurality of sensors 102, a control unit 104 and a server 120. The present disclosure is now described with reference to Figure 1.

The plurality of sensors 102 are configured to sense parameters associated with the CNC machine 114. The parameters associated with the CNC machine 114 are hydraulic and lubrication oil level, temperature of hydraulic oil, hydraulic and lubrication filter clogging, leakage rate of hydraulic pump, spindle drive motor current, CNC axes motor current, calibration of the system, vibrations on tool slides, working of electrostatic filtration unit, working of hydraulic oil chiller unit, spindle rotation speed, gripper and center sleeve pressure, battery and cooling units of the CNC machine, battery of UPS for CNC machine and other parameters associated with the CNC machine. The sensors 102 are selected from a group consisting of optical sensors, vibration sensors, sound sensors, pressure sensor, flow sensor, electromagnetic sensor, current sensor, voltage sensor and combination thereof. The sensors are configured to generate a plurality of sensed values corresponding to respective sensed parameters.

The control unit 104 is configured to cooperate with the sensors 102, to receive the sensed value, compare the sensed values with a corresponding pre-determined threshold values, generate at least one alert based on the comparison and transmitted to a server 120. The server 120 is further configured to log the alerts and transmits the alerts to a remotely located user device 116 associated with a user.

The control unit 104 includes a repository 106, a crawler and extractor 108 and a comparator

110. The repository 106 is configured to store a look up table having a list of the parameters and a first and second threshold values corresponding to each of the parameters. The crawler and extractor 108 is configured to cooperate with the repository 106 to crawl through the look up table to extract the first threshold value and the second threshold value corresponding to each of the sensed parameters. The comparator 110 is configured to cooperate with the crawler and extractor 108 to compare the sensed values with the extracted first threshold value and the second threshold value and to generate a first comparison value and a second comparison value respectively.

In an embodiment, the control unit 104 includes an alert generation module 112. The alert generation module 112 is configured to generate alerts based on the comparison values. The first alert is based on the first comparison value and the control unit 104 transmits the first alert to the server 120. The second alert is based on the second comparison value and the control unit 104 transmits the second alert to the server 120.

In an embodiment, the control unit 104 is configured to generate a stop signal on generation of the second alert. The control unit 104 is configured to transmit the stop signal to the CNC machine 114 to stop the functioning.

The crawler and extractor 108, the comparator 110 and the alert generation module 112 is implemented using one or more processor. The processor may be implemented as one or more microprocessors, microcomputers, digital signal processors, central processing units, state systems, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor is configured to fetch and execute the predetermined set of rules stored in the repository.

In yet another embodiment the sensors 102 are configured to sense parameters associated with an article loaded in between dead centers of the CNC machine 114. The parameters associated with the article are the dimensions of the article before and after a machine processing. If there is any sign of defect in the article, the server 120 generates first alert (caution alert) to the user associated device 116 and the server continues to generate first alert till a corrective measure is taken by the user or till the second alert (failure alert) is generated to stop the functioning of the CNC machine 114.

The CNC machine continues to work even when the first alert is generated. In still another embodiment, a first communication module 118a is configured to communicate between the control unit 104 and the sensors 102, a second communication module 118b is configured to communicate between the server 120 and the user device 116 and a third communication module 118c is configured to communicate between the server 120 and the control unit 104.

In another embodiment, the system 100 is configured to predict the failure of the CNC machine 114 based on:

1. archived sensed values pre-stored in the repository 106;

2. logs stored in the server 120 and the control unit 104; and 3. a set of pre-determined prediction rules pre-stored in the repository 106.

In an embodiment, the server 120 is connected to the multiple CNC machines 114 using high speed internet connection. In another embodiment the server can also be on a cloud.

In yet another embodiment, the alerts are generated under the situations such as: a. A caution alert is generated when the amount of oil in hydraulic and lubrication oil tanks, equipped with suitable float controls, falls below the required level. If the caution alert is not attended, a failure alert will be generated once the oil level drops further below a safe operating level. b. A caution alert is generated is generated when the temperature of the oil in the hydraulic oil tanks varies from the necessary temperature range. If the caution alert is not attended, a failure alert will be generated once the hydraulic oil temperature increases beyond a safe operating level. c. A caution alert is generated in case of clogging of hydraulic and lubrication filter. The filter is equipped with a pressure sensor. The sensor monitors the differential pressure across the filter element of the filter. As the filter element becomes dirty, the differential pressure across the filter element increases. Once the filter element reaches a particular dirty level, the caution alert is generated. If the filter element is not cleaned or replaced within reasonable time, a failure alert will be generated. d. The hydraulic system of the CNC machine is equipped with a variable displacement pump, where there is no discharge from the pump to the actuators when the set pressure is achieved. This reduces temperature rise of hydraulic oil and saves the energy. A very small quantity of oil is leaked through the leakage port of the pump. The amount of oil leaking from the pump is an indication of the health of the pump. As per pump manufacturers, maximum permitted rate of leakage of the oil is pre defined. Once this leakage reaches a maximum permitted level, the pump needs to be repaired or replaced. Hence, the leakage rate of the pump is continuously monitored by means of a suitable sensor and a caution alert is generated sufficiently in advance before generating a failure alert. e. The spindle drive motor current is continuously monitored. Maximum permissible current for the motor is pre-defined by the motor manufacturer. A caution alert is generated sufficiently in advance to take necessary corrective actions. The failure alert is generated once the maximum permitted current is reached. f. The CNC axes motor current is continuously monitored. Maximum permissible current for the motor is pre-defined by the motor manufacturer. A caution alert is generated sufficiently in advance to take necessary corrective actions. A failure alert is generated once the maximum permitted current is reached. g. The measurement system of the CNC machine needs to be periodically calibrated on the master wheel supplied along with the system to ensure consistent and accurate measurement of the wheel. A caution alert will be generated before generating a failure alert, since the system use after a pre-set time period is forbidden without calibrating the system. h. The tool-slide assembly of the CNC machine will be equipped with a vibration detection sensor. A caution alert and a failure alert will be generated based on the misalignment of the tool-slide assembly. i. The CNC machine is equipped with an electrostatic filtration unit for continuous filtration of hydraulic oil to ensure reliable working of the system. The filtration unit draws oil from the tank of hydraulic power unit and after passing through the filters, the oil is again transferred back to the hydraulic power unit. Flow sensor is provided with both caution and failure alerts. In case of reduced oil flow to the electrostatic filtration unit, the caution alert will be generated to replace the filter elements. In case not attended, the failure alert will be generated. j. The oil chiller is provided for continuous control of hydraulic oil temperature to ensure reliable working of the system. In addition to temperature monitoring, the actual flow of the hydraulic oil through the chiller unit is also detected with the help of a flow sensor. In case of a drop in oil flow, a caution alert is generated. In case of a further drop in hydraulic oil flow, a failure alert is generated. k. The spindle rotation speed is continuously monitored during the wheel profiling operation with respect to its set speed. In case of a drop in the speed within a permissible limit, a caution alert is generated. In case, if the speed is further dropped beyond acceptable limits, a failure alert is generated. l. The gripper and center sleeve pressure will be continuously monitored during the wheel profiling operation. Clamping pressure for gripper and center sleeve is very important for proper wheel profiling operation. Both these pressures will be continuously monitored by a pressure sensor during the wheel profiling operation. In case, of a drop in pressure within a permissible limit, a caution alert will be generated. In case, if the pressure further drops beyond the acceptable limits, a failure alert will be generated. m. The supply voltage of battery used in the CNC machine is continuously monitored. In case of a drop in the voltage within permissible limit, a caution alert is generated to arrange for a new battery for CNC machine. In case, of a further drop in voltage, a failure alert is generated. n. An uninterruptible power supply (UPS) is used to ensure uninterrupted electrical supply to the CNC machine. The supply voltage of UPS battery will be continuously monitored. In case of a drop in the voltage within a permissible limit, a caution alert is generated to arrange for new battery. In case of a further drop in the voltage, a failure alert is generated.

The number of parts of the CNC machine that need to be monitored can be increased or decreased based on the application of the CNC machine and future advancement, and should not be construed as limitations of the system of the present disclosure.

In an embodiment, the alert generation module 112 generates instantaneous notification such as an email, text message, pop-ups to the user device 116. In another embodiment, the user may be authorized personnel of a manufacturer, specialized services employing experts and/or authorized representative of CNC machine buyer.

The system 100 of the present disclosure ensures timely maintenance of the CNC machine 114, thereby reducing failure and breakdown time of the CNC machine 114, and increases the reliability, efficiency and availability of the CNC machine 114.

The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a performance monitoring system of a CNC machine, that:

• decreases the failure rate of a CNC machines;

• predicts the failure of the components of the CNC machines; and

• eliminates economic losses due to failure.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in term of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.