2.

0 Technological advancements of CNC technology

2.1 CNC technology advancement using IoT and Cloud Computing.

IoT known as the Industrial Internet of Things (IIoT), and it promises to change the
paradigm in the industry. It makes sense for manufacturers to be patient before there are
established cases of usage before making a leap. Research indicates that the industrial portion
of the IoT including software, hardware and system solutions in the manufacturing,
infrastructure, building and utilities sectors. IoT gives the ability to make integration between
sensors and things by using the internet as a communication medium, which gives developers
a wide area to take benefit of it.

The objective of implementing IoT in CNC technology is to create a system that

having the ability to gather and transfer data, processing, and reporting for workshop’s
machines. Some of the workshop’s machines have a Distributive Numerical Control (DNC)
option in its platform that made it easy to connect to DNC network. DNC mean a number of
numerical control equipment directly connected to a computer or multiple networks
connected with each other. Every workshop has various types of machines which have
different type of operation system platform and output device ports. According to Zhong et
al. (2017), IoT-enabled manufacturing refers to an advanced principle which typical
production resources are converted into smart manufacturing objects that are able to sense,
interconnect, and interact with each other to automatically and adaptively carry out
manufacturing logics.

The wireless controller system. This system consists of Central Computer and the
wireless devices that connected to Machine Control Unit (MCU) of the machine to make
wireless network. For this system, the aim is to use a low-cost embedded Serial port,
Ethernet and Wireless Network (UART-ETH-Wi-Fi module). UART-ETH-Wi-Fi module
offer Wi-Fi possibility to transfer data to different types of machines. Embedded UART-
ETH-Wi-Fi module based on universal serial interface network standard which enable the
user to interface between the conversions.

Any computer with wireless capability like personal laptop or Pad can connect to the
CNC machine and become the device under Wi-Fi Local Area Network (LAN)) and more
of that was having capability to become a part with other network connected to internet
through Wide Area Network (WAN). WAN default IS Internet Protocol (IP) is dynamic IP
address. IP address is an identifying number that associated with a specific computer or
computer network. When connected to internet, IP addree allow the computer to send or
receive the information from the CNC machine. Lan, Wi-Fi for the same local area network,
enabled by default Dynamic Host Configuration Control (DHCP). DHCP automate the
management and configuration IP address across a network, so that IP do not need to be
manually assigned by an admin each time a device connects.

According to Al-Saedei et al. (2017), IoT for CNC Machine Monitoring. During the
machining process of the workpiece. the simulation and automation centre need a real time
data information about vibration, temperature, humidity, noise level, accelerometers,
rotation, and object detection. The real time data information use to make the right decision
if any problem happen. IoT for CNC monitoring consists of:

i. Sensing unit.
Each sensing unit consist of Bluetooth Low Energy chip, printed circuit board
(PCB) and Li/ion coin cell battery. This unis consists of multiple sensors, such as:
(a) Temperature/Humidity
(b) Accelerometers/Gyroscope

ii. Middleware
All sensors will connect to master unit by using BLE to crate Node, this node
must connect to the internet by Wi-Fi via gateway like a wireless router.

iii. Application and User Interface

 Sensor unit must be defined to the cloud server after connected with the master
unit and the master unit must be connected to the internet. The application use is
Relayr. User must create account with an email. This account pair the specific
master unit with its relevant sensing unit. Only master unit able to collect the data
and transmit the data to the cloud platform. The data will be available for user
interface application. The dashboard app posts a request to the cloud server
Application Programming Interface (API) to register a new device. API process
the request and returns a set of Identification (ID) to be written to the master unit
and the sixth sensor unit. Once all sensing unit setup with master unit and
connected to the internet, the real-time sensor data can be viewed on webpage
(Device Dashboard). Real-time sensor data will let know if and how the devices
are communicating also can detect troubleshoot.

2.2 Digitization of CNC technology.

Digitization is mainly about data collection on a bigger scale than before. Most of this
information comes from sensors installed in physical assets factories and machine shops,
including handling equipment, lathes, CNC machines, cutting tools and more. Data from
these sensors provide a variety of information about the function and condition of the system,
including any out-of-spec readings such as unusual temperatures or vibrations. In this way,
digitization provides a virtual representation of the operation from start to finish including
real-time details on any emerging problems that could lead to a malfunction of the equipment
or a compromise in the quality of the workpiece.

CNC technology is convenience because CNC machine’s mechanism that eliminate

manual work, saving time and making manufacturing processes more efficient. Automated
efficiency is quicker than human-driven work. Digitized manufacturing also helps minimize
human error and can run regardless of the day of the week. Many workers face fears from
their teams that machines will replace them. For fact, CNC machines do not replace the
workers, but will inspire the workers and make their work more enjoyable.
 CNC machining makes prototyping more affordable and easier to attain. Prototyping
is essential in manufacturing sectors. Prototyping helps to avoid mistakes later, on the
production process and to understand the product better. Unfortunately, many businesses skip
the prototyping part also do not invest so much time to build a prototype because it is time
consuming and expensive. Now, manufacturers can have a better idea of the further steps
during the production process. The new technology from CNC machines navigates through
manufacturing and allows developing more comprehensive designs.

On top of that, CNC technology does not need many additional parts like separate
frills or sanders, because it has everything incorporated in the main body. CNC machining
drives sustainability in different ways. CNC technology does not require much additional
materials and thereby do not leave as much waste. CNC machining also has fewer chances of
making mistakes, which saves from throwing materials and parts away and wasting precious
production time. Computers and software are the main parts of monitoring a CNC machine.
CAD model preprograms desired projects and uploads information directly to the device. The
benefit from CNC technology is that it can perform almost all producing steps by itself,
eliminating the need for additional tools and machines, or manual work.

Production processes require multiple steps, machines, and the collaboration between
partners. Digitization tools like proactive maintenance keep everybody on the same page.
Digitization and digital quality assurance standards merge process data with product and
manufacturing data. Nothing gets lost in translation across machine shops, and workers can
open product models in a variety of visualization and testing programs with all procedural
data intact. The result from digitization of CNC technology is an industry that more
productive, less wasteful and far more collaborative than it is today. Implementing
digitization is crucial to succeeding in today’s world. It does not make the company stand out
from competitors but also accelerates business operations and workforce performance.

There are many benefits from CNC digitization. Firstly, better customer data. Users
can transmit results to suppliers, thus resulting in better recommendations and product
refinements. Secondly, increased efficiency. Maintaining up-to-date information is much
easier. Lastly, ease of use. Allows cutting tools brands to digitize without creating proprietary
system. Over time, there is no stopping the movement toward data-driven manufacturing. The
availability of cutting tool data in an importable, digital format is giving this movement
added momentum.

2.3. CNC system integration

CNC machines can be set up to operate finishing and service at night only if operator
does it properly. The operator must inspect that the cutting tool is not worn out and that the
programmed parameters are set. The CNC machine can not detect the wear of a tool bit. The
thermal expansion of the unit is another parameter that needs to be carefully controlled.
Although thermal expansion algorithms can help predict when the tool is out of tolerance,
there is still a need for an operator to change the alert indicators per tool.

CNC systems also double as edge computing devices as they are lifted or built with
data-capturing, processing, and reporting features. The standard CNC mobile system consists
of a mobile platform that allows the CNC robot machining arm to be moved from one
location to another with ease. The system also integrates CNC control which provides
platform for using software applications to control the movement and operations of the
machine. Thus, to optimize production efficiency, reduce downtime, increase machining
accuracy, and automate machining processes, CNC systems were developed and currently
being used across diverse industrial niches.

Integration with CAD/CAM platforms. Computer-aided design (CAD) and computer-

aided manufacturing (CAM) software introduced digitization to manufacturing operations.
CAM tools have made digital manufacturing reality and the CNC mobile system is one of its
beneficiaries. CNC mobile machines use the comprehensive models and real-time
information provided by the CAM applications to ensure that several parts are machined
precisely. The input CAM provides data on material tolerance, measurements, and design.
The input data is obtained by the code control language unit of the CNC mobile computer,
which directs the axis movement of the machine tool. This removes human error while
maintaining continuity in the machining process.

There is no need to remotely manage and track these devices. Increased use of IIoT
also presented opportunities for exploring the use of mobile apps to control and link CNC
systems to existing network and systems. CNC mobile applications are used to view the
status of a mobile system, collect machine data, and send notifications concerning its
performance to operators. The ability to achieve this makes automation easier and provides
the data needed to drive Industry 4.0 concepts.

IIoT has allowed for more efficient collection and monitoring of data. Modern
industrial processes can now be scrutinized, analyzed, and adapted more than ever.
Technological advances have heralded a new age of innovation, often referred to as the 4 th
Industrial Revolution or Industry 4.0. Data-driven plant performance optimization is one of
the concepts use in CNC system integration. There are four stages of data-driven plant
optimization. The typical data cycle for plant optimization is as follows:

i. Record and monitor data

Real-time data recording, such as speed of operation, wear and tear, engine use,
and energy use are carried out using IoT sensors.

ii. Upload of data

All data is wirelessly transmitted to a cloud storage system that is also referred to
as the commercial cloud.

iii. Analysis of data

The data is automatically fed into simulation software or a virtual plant model and
data insights generated.

iv. Report and action

 Reports are automatically produced and can be sent remotely to the relevant
people. In some cases, automatic action will be taken such as ordering
replacement parts/

Overall Equipment Effectiveness (OEE) is a measure of how effectively industrial

equipment and plant performs. OEE done by calculating percentage, with 100% representing
perfectly optimised plant performance. OEE measure three areas which are quality,
performance, and availability. A process that scores 100% in all three areas would show good
quality output, as fast as possible, with zero CNC machine downtime. OEE can be linked to
the losses caused by less than 100% optimization, making it a powerful way to reduce costs
and improve profits. OEE involves collecting a lot of data from all plant and machinery
operations, analyzing it thoroughly and gaining insights to improve performance.

There are benefits of OEE and data-driven plant performance optimization. Such as
increased automation. As example, a spare part that frequently need replacing can be
monitored closely for wear by a sensor. Another major benefit is the modern optimization
system are capable of automatically adjusting production volume according to demand or
manufacturing material prices.

2.4 Big data analytic for CNC machining

Data hold the promise to transform manufacturing. Data increasing ease and
advancing capabilities for interconnecting machines, sensing and gathering useful
information, guiding machines automatically, and finding insights in the data flowing out of
manufacturing system. The IoT space is hot as manufacturing represents perhaps the largest
greenfield opportunity left for digitization. IoT coming to maturity and starting to gain
momentum within the industrial space, manufacturers are now able to leverage a whole net
set of data to drive decisions with.
 Big data are characterized by big variety, big volume, and big velocity. In
manufacturing industry, data are generated along the lifecycle of products when orders are
placed to the selected manufacturers, produced by machine tools, and delivered customers.
Big data in machining is extremely difficult, to optimise the entire process from order to final
part using the conventional methods. A manufacturer must concern about the machining
efficiency, cost, and quality, whereas in machining, the right decisions of machine tools,
machining conditions and cutting tools are the major objectives. The relationship between the
machining related elements also complex and include physical and chemical interactions.
Many parameters are needed to represent these elements:

i. Geometric constraint

ii. Cutting force

iii. Cutting layer

iv. Strength of cutting tool

v. High temperature material and tribology

vi. Chemical reaction

However, the process can be represented by using data attributes. The attributes of big
data include the information regarding workpiece, machining requirements, machine tools,
cutting tools, machining conditions, and machining results stated by JI et al. (2018). Also, the
details of the information cover all the factors affecting the machining process, include:

i. Data attributes of workpiece

Workpiece information includes the quantity of parts, parts geometry, and part
materials.

ii. Data attributes of machining requirements

 The designed machining quality in terms of tolerances and surface integrity.

iii. Data attributes of machine tool

Involves the number of machine tool, machine type, machine structure,
structure and power of spindle, linear axis and rotational axis, errors of each
axis, energy consumption of each component, and other related parameters.

iv. Data attributes of machining conditions

Includes cutting parameters, cutting coolant and its parameters.

v. Data attributes of cutting tool

The cutting tool involves tool type, tool material, tool coating, and tool
geometrical parameters.

vi. Data attributes of machining results

Indicates the machining quality in terms of geometrical errors and surface
integrity against the machining requirements.

Machine-generated data is information automatically generated by a computer

process, application, or other mechanisms without the active intervention of a human. The
determination of machining features from a product model is straightforward of the form
features created by a designer match the machining features recognizable by a process
planner or operation planner. However, if the design features do not match the recognizable
machining features, the product data include information on machining features but not
explicit descriptions of them. According to Ji et al. (2018), the attributes of the data
generation include:

i. Workpiece consists of machining feature and material information.

ii. Machining requirements refer to the dimensional tolerances.

 iii. Multi-axis CNC machine tools are the major equipment to perform machining.
Machine tool data include machine tool structure, linear axis errors, rotational axis
errors, and maximum spindle power.

iv. Carbide cutting tools are selected since they are most popularly used in
machining.

v. Coolant and cutting parameter are also crucial in machining beside machining tool
and cutting tool.

vi. Machining results obtained from dimension and surface integrity against the
machining requirements.

2.5 Monitoring of CNC machine and productivity.

IoT and mobile enable us to collect and transfer data, cloud, and Big Data support
store and analyze the collected data efficiently, and analytics, such as machine learning and
deep learning, provide valuable information for decision making of human’s intellectual
work. This new factory model could play an essential role in reducing environmental impacts
on sustainable manufacturing. Most manufacturing companies in developed countries have
faced a lack of workforce and a decline in labor productivity, due to aging population and
low birth rates for the past decades.

Monitoring of CNC machine tools has been a subject of research. Most common
objectives of monitoring applications are tool condition monitoring and monitoring for
maintenance. With additional sensors, such as laser beams, dynamometers, torque sensors,
strain gauges and vision cameras, condition of components related to the accuracy and
precision of the machining were identified, including tool wear and axes performance. CNC
machine tools is one of the widely used of processing equipment needed to make a product
with a Numerical Control (NC) part program. While setting up and running a machine tool,
operators can monitor operational data via a specific Human Machine Interface (HMI) of the
machine tool and are responsible for checking and operational status and changing work
pieces after machining part.
 A real-time monitoring system needs to be considered incorporating to reduce the idle
time and the efforts for manual monitoring of machine tools which are unproductive on the
part of employees or machines as a result of factors beyond their control. The monitoring also
considered essential for reducing energy consumption and environmental impact, due to the
increasing interest in the resources crisis and environmental pollution state by Kim et al.
(2019).

Most network administrators inconveniently run commands via Command Line

Interface to their network devices or else Remote Desktop to their servers to check for current
productivity performances. These processes can now be simplified with network monitoring
tools. The need for network monitoring tools, such as providing complete visibility into the
IT infrastructure, keeping them updated of the network’s state in real time, identifying issues
before the end uses are affected and tracking troubleshoot performance early.

The architecture of CNC monitoring is composed of software module. Firstly,

communication and data platform in CNC monitoring is to support standardized
communications and data gathering from various smart sensors in IoT network. Next is the
data processing, the monitoring of machine tools \, the operational data can be treated as
events that occurred either at a point in time or over a range if time. Using event processing
technologies can support to detect particular pattern of higher-level abstract events, as well as
simple events, and react to them in a real-time manner. Lastly, the data visualization. Data
visualization is an online-monitoring applications via web pages is developed for data
visualization. The advantages of web-based tools are not only familiar user interface, but also
good accessibility to the resources and knowledge.

In the monitoring task, real-time ad automated monitoring from a remote place can
significantly decrease the monitoring complexity of distributed machine tools. Hence,
operators have the advantage of reduced monitoring task and can focus on more valuable
tasks to complete the scheduled production plan. Moreover, using the event processing in the
cloud, such as checking the status of operation, can reduce the unproductive time until
noticing the unwanted issues like alarms, as well as for watching machine tools.

From economic point of view, direct costs of the propose system highly depended on
the hardware used. Most of the software and libraries used in the implementation of the
prototype were freeware or open-source software, but showed enough performance
comparable to commercial products.

2.6 Smart Machine Shop

The Machine Shop 4.0 is aiming to support the convergence of the physical and the
digital worlds. According to Mourtzis et al. (2018), the digitalisation of the machine shop to
accomplish consists of 3 phases. The first phase is the model’s design. The Unified
Modelling Language UML is used. In this process, the key entities of the system and they
identify their attributes. Machine Shop 4.0 is built on the basis of the key performance
indicator calculation and support for maintenance activities. The machine shop, the source,
the variable, and the process are therefore the entities of the model. The second phase toward
this digitalisation is the identification of the digitalisation. Standard for communications that
will enforce the model and will expose it to the cyber world.

The third phase relates to the collection of data from Machine Shop 4.0. In a number
of possible ways, this can be achieved. Manual data entry is the common means of collecting
data from the operation of the production system. Moreover, the latest advances in the
semiconductor industry enable monitoring systems to be installed through production. In
addition, through well-adopted communication interfaces, modern manufacturing resources
provide embedded monitoring capabilities. The parameters that can be obtained through a
combination of the aforementioned data capture practices are modelled in light of these facts.
Moreover, it is a fact that up 10% of machines in factories around the world are older than 15
years, while the lifecycle of industrial equipment may reach 50 years. Therefore, the
development in the Machine Shop 4.0 of a data acquisition device for the integration of
legacy resources.

This capability supports the detailed modelling of resources and their subcomponents,
along with their relationships, in the context of machine shop 4.0. Therefore, by means of a
semantic representation of the data, the data consumer can browse the information model
without requiring prior knowledge of the information model. In addition, semantically
heterogeneous data models can be integrated into a common domain model, in order to
achieve unification during runtime, through appropriate mapping. The proposed Machine
Shop 4.0 includes the guidelines for implementing Cyber-Physical Production System. In
order to support precise decision making, the Machine Shop 4.0 data is available for
consumption through integration with industrial software.