Real Time Monitoring of Ultra-Precision Machining Center
Problem statement
0.1 degrees celsius might not seem like a big temperature difference, but in the world of ultra-precision machining a change that small could cause a machining error and throw the entire part out of specification causing it to be junk. The main contributor to these random errors is thermo mechanical deformation due to different parts of the machine expanding with changes in temperature [1]. Ultra-precision machining works on the nanometer level, with the resolution and random errors being no more than 10nm [2]. So, even a very small expansion of machine components would be capable of increasing the error beyond that threshold. Monitoring the environment that these machines are running in would be extremely beneficial to the manufacturing facilities, as they would be able to stop the machine as soon as the temperature moves out of specification before the part can be mis-machined. Right now, our clients have no means of monitoring the temperature in the enclosure that the machine is running in remotely. The only way is to periodically walk to the room and check, but by then the damage may have already been done if the air conditioner broke during that time. We plan to create a real-time monitoring system to watch over the ultra-precision machining center so that the temperature and humidity can be monitored remotely from an office, and also send out an alert if these values move out of specification. This would allow the client to turn off the machine promptly. This system could also reduce downtime in many different manufacturing applications where there are many cnc machines producing parts repeatedly with no operator immediately supervising them. This system would be able to monitor the various machine parameters and if one parameter moves out of specification, an alert could be sent to the supervisor and the machines could be shut down before hundreds or thousands of parts are created incorrectly. [1] T. N. Reddy, V. Shanmugaraj, V. Prakash, S. G. Krishna, S. Narendranath, and P. V. S. Kumar, “Real-time Thermal Error Compensation Module for Intelligent Ultra Precision Turning Machine (iUPTM),” Procedia Mater. Sci., vol. 6, pp. 1981–1988, Jan. 2014, doi: 10.1016/j.mspro.2014.07.233. [2] N. Taniguchi, “Current Status in, and Future Trends of, Ultraprecision Machining and Ultrafine Materials Processing,” CIRP Ann., vol. 32, no. 2, pp. 573–582, Jan. 1983, doi: 10.1016/S0007-8506(07)60185-1.
Team members
Cooper Kulmaczewski – leader
Ryan Gebert – communicator
Dylan Gessert – accountant
Colton Klecker – admin
Caden Peterson
Client
Vignesh Selvaraj