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Procedia CIRP
CIRP 00
00 (2019)
(2019) 000–000
ScienceDirect
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000–000
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Procedia Procedia
CIRP 00 CIRP
(2017)102
000–000
(2021) 314–318
www.elsevier.com/locate/procedia

18th
18th CIRP
CIRP Conference
Conference on
on Modeling
Modeling of
of Machining
Machining Operations
Operations

Condition
Condition monitoring
28th CIRPbased
monitoring based on
on IoT
IoT for
Design Conference, for predictive
predictive
May maintenance
maintenance
2018, Nantes, France of
of CNC
CNC
machines
machines
A new methodology to analyze the functional and physical architecture of
Yahya
Yahya Mohammed
existing productsAl-Naggar
Mohammed
aa
,, Norlida
for an assembly
Al-Naggar Norlida Jamil
Jamil
aa
,, Mohd
oriented Firdaus Hassan
Mohd product
Firdaus Hassan
family
bb
andidentification
and Ahmad Razlan
Ahmad Razlan
aa
Yusoff
Yusoff * *
Department
a
a Paul Stief *, Jean-Yves
College of Dantan,
Engineering, Alain
Universiti Etienne,
Department of Industrial Engineering, College of Engineering, Universiti Malaysia
of Industrial Engineering, Malaysia Pahang, Ali Siadat
Pahang, 26300
26300 Kuantan,
Kuantan, Pahang,
Pahang, Malaysia
Malaysia
b Department
Department ofof Mechanical
Mechanical Engineering,
Engineering, College
College of
of Engineering,
Engineering, Universiti
Universiti Malaysia
Malaysia Pahang, 26300 Kuantan,
Kuantan, Pahang,
Pahang, Malaysia
Malaysia
b
Pahang, 26300
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

** Corresponding
Corresponding author.
author. Tel.:
Tel.: +60139339934.
+60139339934. E-mail
E-mail address: [email protected]
address: [email protected]
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]

Abstract
Abstract
Abstract
Machining
Machining operation
operation must
must be
be maintained
maintained forfor aa long
long time
time in in every
every period
period to
to achieve
achieve high
high productivity
productivity and
and prevent
prevent sudden
sudden failure
failure or
or breakdown.
breakdown.
InThis
today’s the trend variety and
This study aims to monitor conditions of four CNC machines from different places simultaneously using Internet of things (IoT) for
study business
aims to environment,
monitor conditions of towards
four CNC more
machinesproductfrom different customization
places is unbroken.
simultaneously using Due to
Internet this
of development,
things (IoT) forthe need of
predictive
predictive
maintenance.
agile
maintenance. Vibration
Vibration signals
and reconfigurable of
of four
production
signals CNC
systems
four machines
machinestoare
CNC emerged are measured
cope using
using an
with various
measured accelerometer
products
an to
to collect
and product
accelerometer and
and send
families.
collect signals
To design
send signalsanddirectly to
to the
optimize
directly database
production
the database
in
in real
real time.
systems Results
as well
time. as toshowed
Results choosethat
showed the acceleration
that optimal product
acceleration signal in
in both
both time
signalmatches, product
time and frequency
and analysis
frequency domains
methods
domainsarecan identify
canneeded. conditions
identifyIndeed, mostof
conditions ofofeach
the machine
each in
in real
known methods
machine real time
aimand
time to
and
simultaneously
analyze a productmonitor
simultaneously monitor the
the condition
or one product familyof
condition four
ofon theCNC
four machines
physical
CNC at
at different
level. Different
machines different places
product through
through IoT
placesfamilies, for
for predictive
however,
IoT may differ
predictive maintenance.
largely in terms of the number and
maintenance.
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
© 2021
© 2021 TheThe Authors.
Authors. Published
Published by
by Elsevier B.V.B.V.
system.
© 2021
This is A
an new
The methodology
Authors.
open access Published
article by ELSEVIER
isunder
proposed to analyze
ELSEVIER
the CC
CC B.V.existing
BY-NC-ND products
license in view of their functional and physical architecture. The aim is to cluster
(https://creativecommons.org/licenses/by-nc-nd/4.0)
This products
these
This is an
is an open
openinaccess
access
new article under
assembly
article under the
oriented
the BY-NC-ND
product
CC license
families license
BY-NC-ND for the (https://creativecommons.org/licenses/by-nc-nd/4.0)
optimization of existingonassembly lines and the creation
(https://creativecommons.org/licenses/by-nc-nd/4.0) of future reconfigurable
Peer-review
Peer-review under
under responsibility
responsibility ofofthe
thescientific committee of the 18th CIRP Conference Modeling of Machining Operation.
Peer-review
assembly underBased
systems. responsibility
on Datum the scientific
of Flow scientific committee
physicalof
committee
Chain, the the
the 18th
18thofCIRP
ofstructure CIRP Conference
Conference
the products on
on Modelling
Modelling
is analyzed. of
of Machining
Machining
Functional Operation
Operation
subassemblies are identified, and
Keywords: Predictive
Predictive maintenance; Condition
Condition monitoring;
monitoring; Internet
Internet ofof Things;
Things; vibration
vibration monitoring.
a Keywords:
functional analysis maintenance;
is performed. Moreover, a hybrid functional and physicalmonitoring.
architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review
1. Introductionunder responsibility of the scientific committee of the 28th CIRPprocesses Design Conference 2018.
[2]. Machine-tool maintenance has evolved from
1. Introduction processes [2]. Machine-tool maintenance has evolved from
failure
failure maintenance
maintenance to to preventive
preventive andand predictive
predictive maintenance
maintenance
Keywords: Assembly; Design method; Family identification
Many remarkable things have been invented
Many remarkable things have been invented from all over from all over through
through the years. Early detection of the
the years. Early detection of the machine
machine condition
condition
the world
the world through
through the the years.
years. A machine created
A machine created during
during the the can
can help
help in in predictive
predictive maintenance.
maintenance. Vibration
Vibration analysis
analysis is is
industrial
industrial revolution
revolution has has remarkably
remarkably affectedaffected the the daily
daily lives
lives generally
generally usedused inin the
the predictive
predictive maintenance
maintenance procedure
procedure and and
1.of humans.
humans. Machine
ofIntroduction Machine toolstools play
play an an important
important role role inin the
the global
global of as
theaa product
as support for
for decisions
support range in
in machinery
and characteristics
decisions machinery maintenance.
manufactured
maintenance.and/or This
This
economy. Wang et al. [1] explored
economy. Wang et al. [1] explored 27 major countries 27 major countries type
assembled of analysis can
in this system.
type of analysis be
can be In performed to
this context,
performed avoid the
the main
to avoid occurrence
challenge in
the occurrence of
of
involved in metal
Due toin metal
involved the fastcutting processes
cuttingdevelopment that
processes thatinform form the machine-
thethedomain
machine-of failure.
modelling The increased
andincreased
failure. The level
analysis level
is now of vibration
not only in
of vibration in machines
tomachines
cope with typically
single
typically
tool
tool industry
industry and
communication andcover
and cover 95%
95% of
an ongoing of the total
totalofproduction.
trend
the digitizationThe
production. Theand indicates
products,
indicates the
the imminent
a limited productoccurrence
imminent of
of breakdown
range or existing
occurrence productor
breakdown failure.
orfamilies,
failure.
worldwide
digitalization, machine-tool
manufacturing
worldwide machine-tool production
enterprises
production was
wasare estimated at
facing important
estimated USD
at USD The
butThe nature
alsonature and
to be able severity
to analyze
and severity of machine
of and defect
to compare
machine can be
defect products determined
to define
can be determined
81.2
81.2 billion
billioninin
challenges 2014,
2014, thereby
in today’s marketindicating
thereby that
that the
environments:
indicating theaproduction
continuing
production newand machine
product
and machine failure
families. can be
failureIt can be predicted
be observed
predictedthat via monitoring
viaclassical
monitoring and
existing
and
increment
tendency
incrementtowardsfor machine
reduction
for machine tools in
of product
tools the past
in the development few
past few decadesdecades
times and is
is analysis
product of
families
analysis vibration [3].
are regrouped
of vibration [3]. in function of clients or features.
primarily
shortened due
due to
primarily product to global industrialisation.
lifecycles.
global In addition, there is an increasing
industrialisation. Monitoring
However, assembly
Monitoring the condition
theoriented
condition of
of the
product machine
families
the via
via vibration
are hardly
machine to find.
vibration
The
demand machining
The ofmachining
customization, process is
beingisat the
process widely
same used
widely used in
time inina globalany
any analysis
On the product
analysis provides
provides family many benefits,
level,benefits,
many including
products including
differ mainly increased
in two
increased
manufacturing
competition
manufacturing industry.
industry. allTherefore,
with competitors over the world.
Therefore, machine-tool
This trend,
machine-tool revenue,
main improved
characteristics:
revenue, improved efficiency
(i) the number ofof
efficiency production,
production,andreduced
ofcomponents (ii) the
reduced
maintenance
which is inducing
maintenance systems
systems the play
play aa key
development key role fromin
role ensuring
inmacro
ensuring the
to micro
the downtime,
type of components
downtime, reduced
reduced maintenance
(e.g. mechanical,
maintenance costs, increased
electrical,
costs, availability
electronical).
increased availability
sustainability
markets, of both
resultsofinboth
sustainability machine
diminished
machinelottoolstools and
sizesand manufacturing
due manufacturing
to augmenting of machinery
Classical
of machinery and
methodologies reduced
and reduced stocks
consideringof spare parts
mainlyparts
stocks of spare [4].
single Patil
Patil et
products
[4]. et
product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
2212-8271 ©
© 2021
2021 The Authors.
Authors. Published by
by ELSEVIER
identify
2212-8271 possible The optimizationPublishedpotentials
ELSEVIER in B.V.
the existing
B.V. causes difficulties regarding an efficient definition and
This
This is
is an
an open
open access
access article
article under
under the
the CC
CCtoBY-NC-ND
BY-NC-ND license
license (https://creativecommons.org/licenses/by-nc-nd/4.0)
(https://creativecommons.org/licenses/by-nc-nd/4.0)
production system, it is important have a precise knowledge
Peer-review under responsibility of the scientific committee of the 18th CIRP Conference comparison of different
on Modelling of Machining product
Operationfamilies. Addressing this
Peer-review under responsibility of the scientific committee of the 18th CIRP Conference on Modelling of Machining Operation
2212-8271 © 2021 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-reviewunder
Peer-review under responsibility
responsibility of the
of the scientific
scientific committee
committee of theof28th
the CIRP
18th CIRP
DesignConference
Conferenceon Modeling of Machining Operation.
2018.
10.1016/j.procir.2021.09.054
 Yahya Mohammed Al-Naggar et al. / Procedia CIRP 102 (2021) 314–318 315
2 Yusoff et al./ Procedia CIRP 00 (2021) 000–000

al. [3] ran electrical rotating machines under normal all Raspberry Pi devices in real time. Python is a powerful
operating conditions as the reference test and then applied and modern computer programming language supported by
vibration analysis to monitor their different operating Raspberry Pi [9]. Python software imports raw data from the
conditions. Nolden et al. [4] applied predictive maintenance database in real time to analyse the vibration signal.
using Internet of things (IoT) for condition monitoring of
complex machinery, such as generators. Signals obtained
from vibration sensors in the time domain are converted to
the frequency domain using FFT algorithm in the gateway,
and waveform patterns are analysed for fault detection. Li [5]
performed a similar study but used an advanced processing
technique for predictive maintenance. Tavana et al. [6]
recently reported challenges, open issues and future research
planning using the IoT approach with enterprise (ERP) and
manufacturing (MRP) resource planning systems. Many
companies use MRP and ERP for high-level decision making
because both systems provide centralised data management
according to material planning requirements and integrate
production and purchase processes between companies and
suppliers [7]. However, only large industries can apply these
systems because the total cost of small-to-medium industries
will increase although the integration process can assist big
data management, which is the foundation of data-driven
manufacturing.
A cost-effective predictive maintenance approach is
necessary to ensure that machines can work properly over
many hours of efficient operation with the required accuracy
[1, 2, 5]. A maintenance management system that uses
advanced technologies and techniques for predictive
maintenance, such as IoT sensor communication, is essential
[1, 4, 8]. Condition monitoring is important for predicting
possible failures in machining facilities. Therefore, this study
aims to monitor the condition of IoT-based CNC machines
for predictive maintenance.

2. Methodology

Figure 1 shows the process flow for monitoring the

condition of four CNC machines in real time through IoT and
machine maintenance. MMA8451, the sensor used for
monitoring the machine condition in accelerometers,
demonstrates the advantages of low cost, high precision with
14-bit ADC, wide usage range of ±2 to ±8 g and
compatibility with Arduino and other microcontrollers [5].
The spindle of the machine, which is the source of vibration,
is the optimal location for the sensor. Raspberry Pi 3 Model
B+, a low-cost and a small card-sized device, is the
processing unit of the proposed system and platform for
interfacing with many devices [6]. Virtual network
computing (VNC) is a graphical desktop sharing system that
uses remote frame buffer (RFB) protocol to control another
Fig. 1. Flowchart of the project process
computer remotely. Each IP address of Raspberry Pi is
configured from the VNC viewer with the router. The
Data received from the database in the acceleration term
raspberry pi will then collect raw data from the sensor and
is in the time domain, a(𝑡𝑡). The FFT technique is applied to
send them to the database in real time.
transform the signal from the time domain to the frequency
Figure 2 presents the VNC viewer that can control four
domain as follows:
Raspberry Pi devices with one window. A database is an
organised collection of data generally stored in and 1 ∞
electronically accessed from a computer network. Firebase is 𝑎𝑎(𝑡𝑡) = ∫ 𝜉𝜉(𝜔𝜔)𝑒𝑒 𝑖𝑖𝑖𝑖𝑖𝑖 𝑑𝑑𝑑𝑑, (1)
a service provider of real-time and backend databases. Figure 2𝜋𝜋 −∞
3 shows how the Firebase database receives raw data from
316 Yahya Mohammed Al-Naggar et al. / Procedia CIRP 102 (2021) 314–318
Author name / Procedia CIRP 00 (2019) 000–000 3

unsatisfactory with an orange light or unacceptable with a red

∞
light.
𝜉𝜉(𝜔𝜔) = ∑ 𝑎𝑎𝑡𝑡 𝑒𝑒 −𝑖𝑖𝑖𝑖𝑖𝑖 . (2)
𝑡𝑡=−∞

𝑣𝑣 must be integrated with acceleration to obtain the velocity

as follows:
𝑡𝑡
𝑣𝑣 = ∫ 𝑎𝑎𝑎𝑎𝑎𝑎. (3)
0

RMS velocity (𝑉𝑉𝑅𝑅𝑅𝑅𝑅𝑅 ) is obtained from the velocity to identify

the machine condition as follows:

𝑡𝑡2 (4)
1
𝑉𝑉𝑅𝑅𝑅𝑅𝑅𝑅 = √ ∫ 𝑣𝑣(𝑡𝑡)2 𝑑𝑑𝑑𝑑.
𝑇𝑇
𝑡𝑡1

The sensor reads the spindle vibration after mounting it Fig. 3. Vibration severity according to ISO 10816
on all CNC machines. The sensor is then connected to
Raspberry Pi devices, which must be configured with the IP Machine condition monitoring was simultaneously
address of the workstation router. The Raspberry Pi will send performed on four different CNC machines. The experiment
data to the database in real time. Python is then used to was repeated thrice to compare the value of velocity RMS
import data from the database, analyse the signal in terms of and condition of every machine in each experiment.
acceleration in the time domain and apply the FFT technique
to obtain the acceleration in the frequency domain.
3. Results and Discussion

Figure 4a illustrates the signal of the spindle’s vibration

for CNC 1 in the time and frequency domains. The FFT
graph shows that the peak of acceleration is at 32 Hz. The
velocity RMS value of 1.39 mm/s indicated that the
condition of CNC 1 is satisfactory. Figures 4b and 4c
illustrate the signal of spindle’s vibration for CNC 2 and
CNC 3, respectively, in the time and frequency domains. The
FFT graph shows that the peak of acceleration for CNC 2 and
CNC 3 is at 10 and 8 Hz, respectively. Velocity RMS values
of 0.55 and 0.33 mm/s for CNC 2 and CNC 3, respectively,
indicated that both are in good condition. Figure 4d
illustrates the signal of the spindle’s vibration for CNC 4 in
the time and frequency domains. The FFT graph shows that
the peak of acceleration for CNC 4 is at 57 Hz. The value of
velocity RMS at 2.08 mm/s indicated that the condition of
CNC 4 is unsatisfactory.

Fig. 2. Sensors, software and hardware configuration

From acceleration integrated the signal respect of time to

find the velocity. Lastly, the RMS velocity value based on
ISO 10816 is obtained from the velocity. The guideline for
machinery vibration severity shown in Figure 3 can be used
to identify whether the machine condition is good,
satisfactory, unsatisfactory or unacceptable.
A GUI is developed to show the acceleration signal in the
time domain and determine whether the condition of the
machine is good, satisfactory, unsatisfactory or
unacceptable. Four vibration signals (CNC1, CNC2, CNC3
and CNC4) were plotted to demonstrate the amplitude of the
acceleration signal and indicate the status of the machine as
good with a green light, satisfactory with a green light,
A
 Yahya Mohammed Al-Naggar et al. / Procedia CIRP 102 (2021) 314–318 317
4 Yusoff et al./ Procedia CIRP 00 (2021) 000–000

maintenance. Figure 6 shows the GUI for different CNC

machine conditions based on the vibration signal on the rms
velocity according to ISO 10816. The results showed that the
condition of CNC 1 is satisfactory whilst that of CNC 2 and
CNC 3 is good and CNC 4 is unsatisfactory. Lastly, the
acceleration of vibration signals was plotted to monitor four
CNC machines in real time using IoT.

Fig. 5 RMS velocity of four CNC machines in three

experiments

Obtaining an unacceptable condition, which requires a

considerable amount of machine vibration, was very
difficult because all machines in the laboratory are in good
condition. Notably, obtaining an unacceptable condition
by breaking tools for the sake of the experiment is very
difficult and dangerous. CNC 4 only demonstrated an
unsatisfactory condition after three end mill tools were
C broken.

Fig. 6 GUI for monitoring the condition of CNC machines

D
4. Conclusion
Fig. 4. Vibration measurements of four CNC machines
The relationship between the vibration of the machine
Figure 5 presents the comparison of RMS velocity values and failure is obtained by measuring the vibration of the
of four CNC machines in three experiments. The results machine and analysing the signal of vibration to evaluate the
showed that RMS velocity values of four CNC machines are machine condition. Early deduction of the machine state will
close to one other. The relationship between the vibration of help schedule activities and conveniently reduce downtime
the machine and failure is obtained to evaluate the machine and losses for predictive maintenance. The acceleration of
condition by measuring the vibration of the machine and
analysing the signal of vibration. Timely diagnosis of the
machine state can help schedule activities, conveniently
reduce downtime and losses and help in predictive
318 Yahya Mohammed Al-Naggar et al. / Procedia CIRP 102 (2021) 314–318
Author name / Procedia CIRP 00 (2019) 000–000 5

vibration signals was plotted to monitor four CNC machines https://doi.org/10.1109/icccnt.2013.6726711

in real time using IoT. [4] J. Dai, C. P. Chen, X.-Y. Xu, and P. Hu,
"Condition monitoring on complex machinery for
Acknowledgements predictive maintenance and process control," in
2008 IEEE International Conference on Systems,
The authors would like to thank Universiti Malaysia Pahang Man and Cybernetics, 2008: IEEE, pp. 3595-3600,
for funding this research project through the Prototype doi: https://doi.org/10.1109/icsmc.2008.4811856
Research Grant Scheme (Grant no. PDU203214). [5] X. Li, "Predictive Condition Monitoring Of
Rotating Machinery With Application To Gas
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