A Wireless System and Embedded Sensors on Spindle Rotating Tool for Condition Monitoring

In order to avoid unexpected machined parts failure and maintain the machined surface quality, real time tool condition monitoring plays an important role in machining industries. Recent technological advances in wireless systems, allows the sensors to be mounted in rotating parts such as in the milling process. The primary purpose of this paper is to apply a wireless telemetry system to measure the cutting tool vibration and tool tip temperature for tool condition monitoring. In order to collect and transmit the vibration and temperature signals to the data acquisition device, sensor modules consist of data conditioning and wireless transmitter devices which were built-in into a modified tool holder and powered by inductive power transfer system. The performance of the embedded sensors was evaluated by machining AISI P20 tool steel using carbide cutting tool. The results show that the wireless telemetry system is able to collect the machining signals in real time and demonstrate the capability of detection the changes of tool wear during the milling process.