Driver current analysis for sensorless tool breakage monitoring of CNC milling machines

Tool wear and breakage detection is one of the most important problems found during manufacture in automated CNC machines. From several techniques devoted to sense tool condition, driver current monitoring has been used for a sensorless approach. In order to efficiently use the driver current monitoring technique an exhaustive analysis on the nature of the real components of the signal is required. The novelty of this paper is to present a driver current signal analysis to estimate the influence of the most important spurious signal components in order to determine the optimal parameters for signal conditioning. Beside the cutting force signal, the spurious signals considered in the analysis are high-frequency noise, current control commutation and ball screw effects. The analysis is compared with experimental data in order to validate the model and a case study is presented to show the general procedure.