Development and application of a statistically based feature extraction algorithm for monitoring tool wear in Circuit Board Assembly

Vibroacoustic signals of rotating machinery are composed of sums of modulated periodicities, broadband random components, and occasionally a set of transient responses. These signals are not ergodic as the modulated periodicities are partially coherent. Progressive wear of the rotating machine causes the nonlinear structure of the received signal to intensify, and nonlinearity results in transfer of energy between harmonics of the signal's periodic components. Statistics developed from bispectrum and second-order cumulant spectrum estimates of the measured signal are combined with power spectrum amplitudes as feature inputs for standard multivariate classifiers. The higher-order statistics measure, respectively, the extent of nonlinearity and intermodulation of the received signal. Classification results of simulated and actual incipient wear data collected from a controlled experiment drilling circuit boards illustrate the potential of this novel statistical signal processing approach.