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Lathe Machine as Industrie 4.0 Component (CPS)

Conference Paper · June 2019

DOI: 10.1109/ISIE.2019.8781164

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 Lathe Machine as Industrie 4.0 Component (CPS)

Oleg Ryabov, Seisuke Kano, Hiroyuki Sawada, Jonny Herwan

Advanced Manufacturing Research Institute
National Institute of Advanced Industrial Science & Technology (AIST)
Tsukuba, Japan
oleg.r@aist.go.jp

Abstract—Integration of dynamic objects such as lathe conditions.

machine in Cyber Physical Systems requires incorporation of
some specific components like a net of sensors, signal acquisition
and interpretation parts. Information model of Lathe Machine
life, sensors and methods for transferring complete information
about lathe condition at each stage including failure diagnostics
and prediction are considered.
Keywords—CPS for machine tool; sensors; sensor signal
processing; machining monitoring
I. INTRODUCTION
In 2011 a group of leading German companies united in the
Industry-Research Alliance as an advisory group for the
Federal Government stated some new ideas for German
industrial development and integration of cyber space with the
physical world in manufacturing processes [1]. These ideas
were taken as a basis for creating and announcement of new
strategy for industrial development called and widely known at
present as the fourth industrial revolution - “Industrie 4.0” [2].
The trend of industrial development based on deep introduction
of Internet techniques initiated by the German companies and
federal Government has been taken up by practically all
industrially leading countries and companies.
The core of the Industrie 4.0 conceptual approach accepted
by other programs assumes decentralization of all production
processes; planning and control of them with the help of the
Internet technologies. Every element and agent on every level
and stage of industrial manufacturing, - from planning to
machining, from blank simple parts till complex machining
centers, operators, and engineers, - are supposed to have
separate channels for real time interconnection and
communication via the Internet. Such separateness of industrial
production elements and flexible Internet linkage between
them allow better optimization of production processing,
logistics, immediate adaptation of production plan to real
In spite of the variety of architectural model representation
by different programs [3], [4], the coupling of physical items
with the cyber parts of the systems (CPS) becomes the key
element, similar and natural for all of the models. It is assumed
that every real physical item has tight continuous connection
with its mirror image in the Digital Cyber World. To
emphasizing this symbiotic link of the real objects with their
cyber twins the I4.0 team has defined Industrie 4.0 component
as a single element of the RAMI 4.0 tightly integrating
Physical Things with the Digital World (Fig. 1) [5]. As it is
shown in Fig. 1 the Digital World content is accumulated in so
called Administration Shell of the I4.0 component, whereas the
element called as Thing represents the real world content.
Integration of the Real World items and agents with the
Digital World depends on their complexity [6]. The complexity
of production elements depends on internal structure, the
ability to carry any IP unit, and also on stability of properties
and/or status. From this point of view a machining center is one
of the most complex elements of production industry requiring
permanent monitoring of its condition and status by the
Administration Shell. It was proposed to spin off the
integration of machine tools with cyber world into a separate
entity and call it as Cyber-Physical Machine Tool or Machine
Tool 4.0 as it is shown in Fig. 2 [7].
A network of DAQ (data acquisition) devices provides real
time signals related to the machine tool condition and status.
The signals are accepted and interpreted to simulate Machine

Fig.2. Cyber-Physical Machine Tool structure and its integration in

Fig. 1. Industrie 4.0 component of the RAMI 4.0 [5]. Cyber-Physical Production System by [7].

978-1-7281-3666-0/19/$31.00 ©2019 IEEE 1656

Tool Cyber Twin “life” as closely to the real machine as
possible.
The present paper defines a general approach to determine
a set of hardware and software components necessary and
sufficient for correct simulations of Machine Tool conditions to
the problems of real-time remote monitoring, proper decision
making, and flexible control by/via Cyber World. NC lathe was
selected for this particular case study.
II. GENERAL DEFINITION OF TASK
Quality and particularity of Real Thing condition
reproduction in Cyber World tightly depends on quality of data
and information flow acquired from the Real World. In the
case of machine tools when the real situation may vary in a
split second, it is required to cover the machine with a net of
sensors, to continuously monitor it in real time, to process and
transfer the data to Cyber World. Practically all sensors
available for machine tool monitoring refer to the indirect type,
the sensing signals related to monitored object performance
indirectly. So, a part for interpretation of indirect sensor signals
in terms of condition parameters is also required.
Taking into account all the remarks mentioned, a general
system for coupling Machine Tool with Cyber World is
schematically shown in Fig. 3 with the help of Industrie 4.0
component presentation features [3].
III. LATHE MACHINE INFORMATION MODEL
Discussion and analysis of the possible ways for coupling
Lathe machine with Cyber World should be started with
determination of information model, a complete list of
parameters and features which need to be monitored and
transferred to the Cyber Twin. As the present task of lathe
coupling is considered as a part of a general Architectural
Model without specification of any particular goal, it is
preferable to count all possible parameters describing all
Fig. 3. Schematic coupling of Machine with Administration Shell (Cyber
World).
possible conditions and states of the machine tool “life”.
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A. Preparatory period
The initial status of any Machine Tool is the Rest (1), when
the circuit breaker is off, and no electricity coming.
The next several states characterize the steps of consequent
turning on different parts of lathe up to Standby mode, when all
the internal parts are connected to electric power and ready for
cutting operation. It is desirable to distinguish each step of
switching to electric power and Standby Mode (2) by the
sensor network.
B. Machining – normal case
The machining by lathe means removing material from a
rotating workpiece by a single point cutting tool. This process
is characterized by properties of Workpiece Material (3),
parameters of Cutting Tool (4), and parameters of interaction
of tool with workpiece, namely Cutting Speed (5), Feed Rate
(6), and Depth of Cut (7). As a result, the cutting process
generates the workpiece surface of a certain Roughness (8). In
some cases, the machining is accompanied by Lubricant
application (9).
C. Abnormal machining
The machining process may produce a part with form
dimensional features or surface roughness outside acceptable
limits. It happens as a result of defects which may appear in
turning. Workpiece may be insecurely fixed in spindle (10), or
workpiece may be fixed with misalignment (11), or cutting tool
may be insecurely locked on turret (12), or tool may be worn
out during the cutting (13), or tool chipping may take place
(14), or chatter vibration may occur (15). All these factors may
cause abnormal machining and result in scrap.
D. Summary
Thus, the list of parameters and states describing Machine
Tool condition looks as the following;
1 – status Rest, 2 – status Standby (several stages), 3 –
Workpiece Material, 4 – Cutting Tool, 5 – Cutting Speed, 6 –
Feed Rate, 7 – Depth of Cut, 8 – Surface Roughness, 9 –
Lubricant Use, 10 – Workpiece Clamping Error, 11 –
Workpiece Misalignment, 12 – Cutting Tool Fixation Error, 13
– Tool Wear, 14 - Tool Chipping, 15 – Chatter Vibration.
IV. SENSORS
According to the Web of Science Core Collection [8] the
number of publications related to the sensors development and
application for monitoring of machining conditions grows from
year to year.
Longstanding analysis of the of sensing systems directly
and with the help of reviewers, such as Botsaris and Tsanakas
[9], Kovač, P. et al [10], S. Mandal [11], M. Rizal et al [12],
Tran Van Tung and Bo-Suk Yang [13], P. Waydande et al [14],
M. Shiraishi [15], J. Tlusty and G. C. Andrews [16], C.H.
Lauro et al [17], R. Teti et al [18], showed that despite of the
wide range of studies and publications the variety of used
sensors is quite limited and can be grouped by physical
principals in use.
A. Electrical Characteristics Sensors
As a rule, the electric current sensors are applied for
measuring power consumption by different parts of machine
tool or by machine in total. It may provide indirect monitoring
of the particular part motion characteristics.
B. Force/Torque Sensors
Different types of dynamometers are mounted under or
inside cutting tool holders for measuring different components
of cutting force. Torque sensors can measure variations in
rotation of turning parts, such as spindle in case of lathe.
C. Sound Sensors
Machine tool operation and cutting process exhale specific
sounds and noises. Sensing and analysis of audible and/or
ultrasonic signals may be useful for monitoring of machining
conditions.
D. Acoustic Emission Sensors
In addition to the sounds and noises caused by motion and
interaction of machine tool parts during the operation, the
cutting process generates stresses and deformations inside of
materials of cutting tool and workpiece. These structural
changes of materials are accompanied by elastic vibrations of
cutting tools and workpiece. Acoustic Emission sensors
monitor the level of such elastic vibration emission as a signal
indirectly related to the material degradation and distraction
phenomena.
E. Temperature Sensors
Dragging cutting tool edge along the workpiece causes the
heat generation and increases the temperature of the interacting
parts. Temperature of the workpiece during the cutting is one
of the key factors needed to be control. In addition, the heat
generation intensity depends on the cutting tool edge
sharpness. Thus, the temperature monitor may indirectly relate
to the tool edge condition.
F. Visual Sensors
Video camera, high-speed photo camera, 3D laser scanner
can be used for direct monitoring of cutting process
components. Unfortunately, application of the optical sensors
is difficult, on practically impossible in the most of
applications due to heavy duty cutting environment.
G. Pressure Sensors
Motion of some parts of machine tools is controlled with
the help of hydraulic system. Application of the pressure
sensors for sensing the machine tool may provide indirect
information of the motion of those parts.
H. Vibration/Acceleration Sensors
Rotation and motion of machine tool parts, as well as the
cutting process itself generates vibration. The level and/or
frequency distribution of vibration spectrum may depend on
cutting condition. Measuring acceleration of machine tool may
indirectly monitor the cutting process.
I. Displacement Sensors
Displacement meters, like touch probes, remote laser
displacement meters, may provide direct information on
position of cutting tool edge, setting of workpiece. These
sensors can hardly be use in real time monitoring. However, it
may be applied before and after cutting process.
J. Sensor integration and fusion
As it has been shown in the previous chapter, the machine
tool condition is characterized by many factors. It is difficult to
expect that application of just one sensor can give complete
information on all the factors. Application and integration of

Table 1. Applicability of Sensors for Machine Tool Monitoring.

Sensors
Electrical Force/ Sound Acoustic Temperature Visual Pressure Vibration/ Displacement
characteristics Torque emission acceleration
status Rest x x x
status Standby x x x
Workpiece Material x x x x
Cutting Tool x x x x
Cutting Speed x x x
Feed Rate x x x
Machine Tool Condition

Depth of Cut x x x
Surface Roughness x x x x
Lubricant Use x x x
Workpiece x x x
Clamping
Workpiece x x x x x
Misalignment
Cutting Tool x x x x
Fixation
Tool Wear x x x x x x
Tool Chipping x x x x x x x
Chatter Vibration x x x x x

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 Fig.4. Schematic view of the data and information flow from Physical to Cyber World.
several sensors is required for completing the picture close to
the real condition of machine tool.
K. Summary
Table 1 summarizes information on practically available
sensors and spectrum of their possible applications for machine
tool monitoring.
V. SENSING SIGNAL PROCESSING AND INTERPRETATION
METHODS
It is important to repeat here the goal of the present task
determination. Sensing signals and their derivatives should be
processes and interpreted to provide information about real
Machine Tool condition for the Cyber Twin. Machine Tool
may be in “normal”, or in “abnormal” conditions. Some kind of
failure may suddenly occur during the cutting operation.
Different methods may be used for Machine Tool state
monitoring, fault diagnosis, and prediction. The CPS may
require all these information for different purposes.
Let us specify the variety of published methods (refer to the
review papers [9], [10], [13], [17], [19]) for signal processing
and interpretation applicable for recognition of different status
of Machine Tool activity.
A. Monitoring
For the purpose cutting parameters monitoring and
interpretation of Machine Tool status it is possible to use the
following techniques: Time series, Fourier transforms, Spectral
analysis, Time domain, Standard histogram analysis,
Thresholding, Statistical parameters & ARMA, GLCM
analysis, Gray level distribution, Wavelet transform, Edge
detection, Cross-correlation function, Fast Hough Transform,
Taylor diagrams.
B. To Diagnose Machine Tool Failure
The following list of methods has been successfully applied
diagnosing of different Machine Tool failures such as tool
wear, and chipping: Pattern recognition, Adaptive Resonance
Theory (ART2), Neural Networks, Linear Regression (LR),
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Fuzzy Logic (FL), Hidden Markov Models (HMM), and
Support Vector Machine (SVM).
C. To Diagnose Machine Tool Failure
AI statistical, model-driven, or data-driven methods are
quite useful for prediction of Machine Tool Failure and
abnormality prediction.
VI. CONCLUSION
Machine Tool 4.0 as a universal Industrie 4.0 component
with capability to solving any possible task related to
monitoring of a real lathe machine running condition requires
integration of several sensors as well as several signal
processing and interpretation methods for sensing of machining
status, diagnosis and prediction of any possible failures in real
time mode. All the possible and available sensors and signal
processing techniques are schematically shown in Fig. 4.
It is a goal of the future work to determine the sensor
network and set of methods sufficient and enough for the
practical implementation in Machine Tool 4.0 case for Lathe.
ACKNOWLEDGMENT
Authors gratefully acknowledge Ministry of Economy,
Trade, and Industry (METI) of Japan for funding the project
entitled: “Standardization of Smart Manufacturing”.
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