Learning to monitor a machine tool

This paper deals with the issue of automatic learning and recognition of various conditions of a machine tool. The ultimate goal of the research discussed in this paper is to develop a comparehensive monitor and control (M&C) system that can substitute for the expert machinist and perform certain critical in-process tasks to assure quality production. The M&C system must reliably recognize and respond to qualitatively different behaviours of the machine tool, learn new behaviors, respond faster than its human counterpart to quality threatening circumstances, and interface with an existing controller. The research considers a series of face-milling anomalies that were subsequently simulated and used as a first step towards establishing the feasibility of employing machine learning as an integral component of the intelligent controller. We address the question of feasibility in two steps. First, it is important to know if the process models (dull tool, broken tool, etc.) can be learned (model learning). And second, if the models are learned, can an algorithm reliably select an appropriate model (distinguish between dull and broken tools) based on input from the model learner and from the sensors (model selection). The results of the simulation-based tests demonstrate that the milling-process anomalies can be learned, and the appropriate model can be reliably selected. Such a model can be subsequently utilized to make compensating in-process machine-tool adjustments. In addition, we observed that the learning curve need not approach the 100% level to be functional.