Wireless Vibration Monitoring System for Milling Process

Abstract

The implementation of industrial revolution 4.0 in manufacturing industries is necessary to adapt to the rapid changes of technologies. The milling process is one of the common manufacturing processes applied in the industries to produce engineering products. The vibration that occurs in the milling process can disturb the continuity of the process. The wired vibration monitoring system implemented in the manufacturing process needs to be replaced with the wireless monitoring system. Hence wireless vibration monitoring system is developed to solve the problem with wired monitoring systems where tucked cable and high cost are the main challenges of the wired monitoring system. The wireless monitoring system setup is built using three components: sensor node, monitoring node, and base station. Milling experiments with various depths of cut, feed rate, and spindle speed were conducted to examine the performance of the wireless monitoring system. The results indicate the wireless system shows similar data recorded by the wired system. The wireless vibration monitoring system can identify the effect of milling parameters such as depth of cut, feed rate, and spindle speed on the vibrations level. The effect of cut depth is more significant than spindle speed and feed rate in the defined parameters.