Measuring via sensors built into the processing machine

As part of the Dynatool European research project that included the integration of monitoring systems into the processing of complex shapes, Sirris together with KU Leuven has been focusing on integrating acoustic and force sensors into the clamping devices used with workpieces. We came up with quite a few interesting findings.

At the beginning of 2015 Sirris and the PMA department at KU Leuven set up the Dynatool research project. It is a European collaborative project involving a number of universities, as well as German and Austrian colleges, and concerns the integration of monitoring technologies and simulation methods for improving control when milling complex shapes.

Various research groups are collaborating on the project that includes the installation of sensors on the machine (on the spindle, tooling and clamps) and processing the resulting measurements. The results have provided an indication of the state of the tools, which means that vibration can be prevented, tool wear (and fractures) can be detected early, and the proper scope of application can be determined. These measurements can provide interesting information for implementing better simulations with new products, thereby resulting in useful interaction.

Schematic summary of the research subjects in the Dynatool project

Integrating sensors

Sirris and KU Leuven have been focusing principally on the integration of acoustic and force sensors on the clamps for workpieces. From the resulting measurements it has emerged that positioning is important. Regarding the acoustic sensors, certain frequency ranges provided information about the actual milling process.

Left: measuring the acoustic emission signals while processing; right: visualising tool fractures by zooming in at the right frequencies 

It has emerged from these studies that multi-sensor solutions (i.e. the combination of several types of measurement) is needed to obtain a better understanding of the condition of the tool. Using smart algorithms, a link was made between the measurements and the amount of wear on the tool.

The foreign project partners focused on installing the sensors into other components. It is possible to bring together the various solutions within the project, and the knowledge gained at the institutions abroad is also available in Belgium. 

The project continues until the end of March thanks to support provided by VLAIO.

Interested? Then contact us now!