An attachable electromagnetic energy harvester driven wireless sensing system demonstrating milling-processes and cutter-wear/breakage-condition monitoring

Tien-Kan Chung*, Po Chen Yeh, Hao Lee, Cheng Mao Lin, Chia Yung Tseng, Wen Tuan Lo, Chieh Min Wang, Wen Chin Wang, Chi Jen Tu, Pei Yuan Tasi, Jui Wen Chang

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

15 Scopus citations

Abstract

An attachable electromagnetic-energy-harvester driven wireless vibration-sensing system for monitoring milling-processes and cutter-wear/breakage-conditions is demonstrated. The system includes an electromagnetic energy harvester, three single-axis Micro Electro-Mechanical Systems (MEMS) accelerometers, a wireless chip module, and corresponding circuits. Theharvester consisting of magnets with a coil uses electromagnetic induction to harness mechanical energy produced by the rotating spindle in milling processes and consequently convert the harnessed energy to electrical output. The electrical output is rectified by the rectification circuit to power the accelerometers and wireless chip module. The harvester, circuits, accelerometer, and wireless chip are integrated as an energy-harvester driven wireless vibration-sensing system. Therefore, this completes a self-powered wireless vibration sensing system. For system testing, a numerical-controlled machining tool with various milling processes is used. According to the test results, the system is fully self-powered and able to successfully sense vibration in the milling processes. Furthermore, by analyzing the vibration signals (i.e., through analyzing the electrical outputs of the accelerometers), criteria are successfully established for the system for real-time accurate simulations of the milling-processes and cutter-conditions (such as cutter-wear conditions and cutter-breaking occurrence). Due to these results, our approach can be applied to most milling and other machining machines in factories to realize more smart machining technologies.

Original languageEnglish
Article number269
JournalSensors (Switzerland)
Volume16
Issue number3
DOIs
StatePublished - 23 Feb 2016

Keywords

  • Attachable
  • Cutter condition
  • Electromagnetic
  • Energy harvester
  • Milling monitoring
  • Self-powered
  • Sensing
  • Vibration
  • Wireless

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