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Self-Powered Wireless Vibration-Sensing System for Machining Monitoring

Tien-Kan Chung*a, Hao Leea, Chia-Yung Tsenga, Wen-Tuan Loa, Chieh-Min Wanga,

Wen-Chin Wangb, Chi-Jen Tub, Pei-Yuan Tasib, and Jui-Wen Changb aDepartment of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan.

bPrecision Machinery Research and Development Center, Taichung 40768, Taiwan.

ABSTRACT

In this paper, we demonstrate an attachable energy-harvester-powered wireless vibration-sensing module for milling-process monitoring. The system consists of an electromagnetic energy harvester, MEMS accelerometer, and wireless module. The harvester consisting of an inductance and magnets utilizes the electromagnetic-induction approach to harvest the mechanical energy from the milling process and subsequently convert the mechanical energy to an electrical energy. Furthermore, through an energy-storage/rectification circuit, the harvested energy is capable of steadily powering both the accelerometer and wireless module. Through integrating the harvester, accelerometer, and wireless module, a self-powered wireless vibration-sensing system is achieved. The test result of the system monitoring the milling process shows the system successfully senses the vibration produced from the milling and subsequently transmits the vibration signals to the terminal computer. Through analyzing the vibration data received by the terminal computer, we establish a criterion for reconstructing the status, condition, and operating-sequence of the milling process. The reconstructed status precisely matches the real status of the milling process. That is, the system is capable of demonstrating a real-time monitoring of the milling process.

Keywords: energy harvester, electromagnetic, power generator, vibration, machining monitoring, self-powered, wireless sensor

1. INTRODUCTION Recently in the society of wireless sensors network, researchers demonstrated an innovative wireless sensing/monitoring application for machining monitoring [1]. In the application, the wireless sensing system is used to sense, analyze, and monitor the temperature of the milling cutter in the machining process. This real-time monitoring prevents the machining failure caused by over-heating in the process and subsequently enhances the reliability of the machining tool. However, the maintenance becomes difficult due to the battery replacement issue in the case of numerous sensors used in a sensor-network. To address this issue, an energy-harvester-powered (i.e., toward self-powered) wireless sensing system is a preferred solution. Nowadays, solar cells are comprehensively used as the energy harvesters for powering the wireless sensing system. However, solar-cell-powered wireless sensing system is not suitable for indoor applications, especially inappropriate for monitoring the machines in a factory. Therefore, researchers use vibrational energy harvesters [2] (such as piezoelectric, electromagnetic, and electrostatic energy harvesters) instead of the solar cells to generate power for the indoor applications. However, the circuit for piezoelectric energy harvesters is more difficult than electromagnetic energy harvesters. Thus, electromagnetic energy harvesters are comprehensively utilized by the researchers to power the wireless sensing systems for the indoor applications. That is, more appropriate for monitoring the machines in a factory. More recently, researchers demonstrated an electromagnetic energy harvester powering a wireless sensing system for health monitoring of a spindle [3]. However, both the harvester and wireless sensing system have to be embedded into the spindle of the machine. Consequently, the spindle must be modified (i.e., customized/non-standard spindle). This causes serious issues in design and manufacturing of the customized/non-standard spindle to both spindle- and machine- manufacturers. More seriously, the customized/non-standard spindle may not be fully compatible with the existing machines. This results serious problems in machining. Therefore, an attachable (i.e., nondestructive for the spindle) self-powered wireless sensing system is needed. Hence, in this paper, we demonstrate an attachable energy-harvester-powered wireless vibration-sensing system for machining monitoring.

*[email protected]; phone 886-3-5712121 ext. 55116; fax 886-3-572-0634

Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems 2013, edited by Jerome Peter Lynch, Chung-Bang Yun, Kon-Well Wang, Proc. of SPIE Vol. 8692,

86922U · © 2013 SPIE · CCC code: 0277-786X/13/$18 · doi: 10.1117/12.2009435

Proc. of SPIE Vol. 8692 86922U-1

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5. CONCLUSION We have successfully demonstrated the energy-harvester-powered (i.e., self-powered) wireless vibration-sensing system for read-time monitoring of a milling-process. The electromagnetic energy harvester harvests the mechanical energy from the milling and subsequently converts the mechanical energy to electrical energy to power the MEMS accelerometer and wireless module. The result shows the system successfully senses the vibration occurred in the milling and subsequently transmits the vibration data (voltage signals) to the terminal computer. Furthermore, based on the criterion we established through analyzing the vibration data received by the terminal computer, the operating-sequence of the milling machine is successfully reconstructed. This achieves a real-time monitoring of the milling process toward an intelligent machining-monitoring system. In the future, we will investigate and develop more advanced smart-machining functions for the self-powered sensing system.

ACKNOWLEDGMENT Support for this work was obtained from the Taiwan National Science Council (NSC Grant No.101-2625-M-009-008 and NSC Grant No. 101-2221-E-009-022).

REFERENCES

[1] Wright, P. K., Dornfeld, D. A., Hillaire, R. G. and Ota, N. K., "A wireless sensor for tool temperature measurement and its integration within a manufacturing system," Transactions of the North American Manufacturing Research Institute of SME. 63-70 (2006).

[2] Chung, T. K., Lee, D. G., Ujihara, M. and Carman, G. P., “Design, simulation, and fabrication of a novel vibration-based magnetic energy harvesting device,” Transducers '07 & Eurosensors XXI, Digest of Technical Papers 1, U438-U439 (2007).

[3] Chang, L. C. and Lee, D. S., "The development of a monitoring system using a wireless and powerless sensing node deployed inside a spindle," Sensors 12(1), 24-41 (2012).

[4] Beeby, S. P., Tudor, M. J. and White, N. M., "Energy harvesting vibration sources for microsystems applications," Measurement Science & Technology 17(12), R175-R195 (2006).

[5] Lei, W., and Yuan, F. G., "Energy harvesting by magnetostrictive material (MsM) for powering wireless sensors in SHM," Proc. SPIE 6529(2), 652941 (2007).

[6] Beeby, S. P., Torah, R. N., Tudor, M. J., Glynne-Jones, P., O'Donnell, T., Saha, C. R., and Roy, S., "A micro electromagnetic generator for vibration energy harvesting," Journal of Micromechanics and Microengineering 17(7), 1257-1265 (2007).

[7] Kulkarni, S., Koukharenko, E., Torah, R., Tudor, J., Beeby, S., O'Donnell, T. and Roy, S., "Design, fabrication and test of integrated micro-scale vibration-based electromagnetic generator," Sensors and Actuators a-Physical 145-146(1-2), 336-342 (2008).

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