title: An Attachable Electromagnetic Energy Harvester Driven Wireless Sensing System Demonstrating Milling-Processes and Cutter-Wear/Breakage-Condition Monitoring.
abstract: An attachable electromagnetic-energy-harvester driven wireless vibration-sensing system for monitoring milling-processes and cutter-wear/breakage-conditions is demonstrated. The system includes an electromagnetic energy harvester, three single-axis Micro Electro-Mechanical Systems (MEMS) accelerometers, a wireless chip module, and corresponding circuits. The harvester consisting of magnets with a coil uses electromagnetic induction to harness mechanical energy produced by the rotating spindle in milling processes and consequently convert the harnessed energy to electrical output. The electrical output is rectified by the rectification circuit to power the accelerometers and wireless chip module. The harvester, circuits, accelerometer, and wireless chip are integrated as an energy-harvester driven wireless vibration-sensing system. Therefore, this completes a self-powered wireless vibration sensing system. For system testing, a numerical-controlled machining tool with various milling processes is used. According to the test results, the system is fully self-powered and able to successfully sense vibration in the milling processes. Furthermore, by analyzing the vibration signals (i.e., through analyzing the electrical outputs of the accelerometers), criteria are successfully established for the system for real-time accurate simulations of the milling-processes and cutter-conditions (such as cutter-wear conditions and cutter-breaking occurrence). Due to these results, our approach can be applied to most milling and other machining machines in factories to realize more smart machining technologies.
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. tkchung@nctu.edu.tw.|International College of Semiconductor Technology, National Chiao Tung University, Hsinchu 30010, Taiwan. tkchung@nctu.edu.tw.
authors.forename: Tien-Kan
authors.initials: TK
authors.lastname: Chung
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. scarletleaf.me02g@nctu.edu.tw.
authors.forename: Po-Chen
authors.initials: PC
authors.lastname: Yeh
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. peter800702.me98@g2.nctu.edu.tw.
authors.forename: Hao
authors.initials: H
authors.lastname: Lee
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. stan86113@gmail.com.
authors.forename: Cheng-Mao
authors.initials: CM
authors.lastname: Lin
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. zxc351763x@yahoo.com.tw.
authors.forename: Chia-Yung
authors.initials: CY
authors.lastname: Tseng
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. william123y@hotmail.com.
authors.forename: Wen-Tuan
authors.initials: WT
authors.lastname: Lo
authors.affiliation: Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan. chmin0217@gmail.com.
authors.forename: Chieh-Min
authors.initials: CM
authors.lastname: Wang
authors.affiliation: Precision Machinery Research Development Center, Taichung 40768, Taiwan. e8702@pmc.org.tw.
authors.forename: Wen-Chin
authors.initials: WC
authors.lastname: Wang
authors.affiliation: Precision Machinery Research Development Center, Taichung 40768, Taiwan. tojijn@gmail.com.
authors.forename: Chi-Jen
authors.initials: CJ
authors.lastname: Tu
authors.affiliation: Precision Machinery Research Development Center, Taichung 40768, Taiwan. e9604@mail.pmc.org.tw.
authors.forename: Pei-Yuan
authors.initials: PY
authors.lastname: Tasi
authors.affiliation: Precision Machinery Research Development Center, Taichung 40768, Taiwan. e9419@pmc.org.tw.
authors.forename: Jui-Wen
authors.initials: JW
authors.lastname: Chang
keywords: attachable; cutter condition; electromagnetic; energy harvester; milling monitoring; self-powered; sensing; vibration; wireless