The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)
IoT Enabled Real-Time Availability and Condition
Monitoring of CNC Machines
2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS) | 978-1-7281-9448-6/20/$31.00 ©2021 IEEE | DOI: 10.1109/IoTaIS50849.2021.9359698
B Siddhartha
Department of Electronics and
Communication Engineering
R. V. College of Engineering
Bangalore, India
siddhartha51997@gmail.com
Dr. Gopala Krishna HD
Mechanical Engineering
Department
R. V. College of Engineering
Bangalore, India
gopalkrishnahd@rvce.edu.in
Abstract—One of the biggest challenges faced by the man-
ufacturing industry is to improve productivity and process
efficiency. Achieving zero downtime has been the goal of
manufacturers since a long time, with the advancement in IoT
making sensors inexpensive and compact with Industry 4.0
revolutionizing the complete manufacturing process, real-time
monitoring and collection of data from all necessary perspectives
can be done remotely. Industries manufacturing at large scale
often find it difficult to monitor the condition of the machines
and manufacturing process. Downtime due to machine faults
and operator negligence contributes to machine inefficiency. This
paper presents a multiple sensor-based condition and availability
monitoring system deployed on a CNC machine. The major steps
for preventive maintenance are daily checking of lubricant level,
inspecting of vibration levels, and temperature of the motor.
The IoT system uses sensors measuring Vibration, Current,
temperature, and coolant levels of CNC machines. A cloud-
based platform is created for displaying of real-time graphs
of important parameters and Overall Equipment Effectiveness.
The data collected from the machine can be used to quickly
diagnose the problem and Availability monitoring can help to
pinpoint the cause of downtime in the process. The proposed
system is useful for remote condition monitoring and data-based
decision-making process.
Index Terms—IoT, CNC Machine, Condition Monitoring,
Availability Monitoring
I. I NTRODUCTION
Industry 4.0 is the digitization of manufacturing and pro-
duction industries. The main aim of industrial 4.0 is to create
an end to end value chain with Industrial Internet of things
and decentralized decision making/intelligence in Manufac-
turing. Cyber-Physical machines for the basic building block
and the Internet of Things (IoT) plays a vital role in the
integration of Industry 4.0.
Industrial Internet of things (IIoT) is a subset of IoT. IIoT
provides insights into the manufacturing process by collecting
data from machine sensors and the integration of cloud. The
data can be used as feedback to analyze the process thus
helping in accelerating productivity, reduction in unplanned
downtime, and optimized efficiency thereby profits. IIoT itself
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Arunkumar P Chavan
Department of Electronics and
Communication Engineering
R. V. College of Engineering
Bangalore, India
arunkumarpc@rvce.edu.in
Dr. K N Subramanya
Department of Industrial Engineering
and Management
R. V. College of Engineering
Bangalore, India
subramanyakn@rvce.edu.in
is not a single system but comprises of various existing
technologies such as Wireless modules, Machine2Machine
communication, sensors, PLC, cloud, and much more. IoT
enables machine connectivity , data management, processing,
and analysis which is vital for condition monitoring of
machines.
Condition Monitoring(CM) is the technique for tracking a
machine’s health and parameters (vibration, Current, Coolant
level, temperature). To detect a major change that is sugges-
tive of developing failure. The major benefit tracking machine
condition in real-time is that industries can avoid unscheduled
downtime, implement preventive maintenance, and collect
data for diagnostics. CM has a major advantage in that flaws
that may reduce the normal lifespan of parts can be fixed
before they evolve into a breakdown.
In today’s manufacturing shop floor huge losses/wastage
such as defects, excess processing happens in the indus-
try shop floor. This wastage maybe because of operator
negligence, improper maintenance, and inefficient process,
tooling issues, and the lack of spare parts at the correct
time. Other wastage includes idle machine time, breakdown,
rejected parts, etc., This production-related wastage is having
significant importance as they deal with the time, profit, and
reputation of the company. The machining process can be
monitored in real-time; these real-time data analytics will
provide insights into any kind of error in the manufacturing
process, machine, and the scheduling of operations. This will
help in identifying early bottlenecks in the manufacturing
process.
In today’s competitive world for industries to be profitable,
it is of utmost importance to run the shop floor with maximum
efficiency and minimal downtime. Downtime due to machine
failure or operator negligence disrupts production, loss of
productivity, and higher costs. A survey of executives in the
manufacturing industry, most say that loss because of down-
time during production is very high with such high costs,
 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)
running at maximum efficiency is critical for an industry to
be profitable. The combination of Condition monitoring IoT
and cloud are new systems used by the industrial sector to
implement smart manufacturing.
The paper presents a novel system design of a low-cost
module for condition monitoring of CNC machines using
parameters such as Vibration, Current, Temperature, and alert
operator in case of any deviation from normal. The proposed
system has two main modules. The first module is used to
collect data from CNC machines and operators. The second
module is a Cloud module and it is used for the storage and
processing of data.
The structure of the paper as follows.After the introduction,
a literature review of the current methodology and current
trends considered in this research are described in detail.The
architecture of the proposed system is presented in the Archi-
tecture Section.Then, a prototype is outlined and implemented
to experimentally validate the proposed system. In the end,
the conclusion and future scope for research are addressed.
II. LITERATURE REVIEW
Over the last few years, tremendous advancement has been
made in the Industrial Internet. The Industrial Internet had
one very simple but important requirement: the ability to re-
motely track machine health and eliminating the requirement
to be in near machines when diagnosing problems. These
early systems were simple alarm systems that would generate
an alert when the machine was overheating and about to fail
The complexity of manufacturing has increased and there
requires an innovative and inexpensive method to monitor
machines. A lot of research has been done in this area and
several methods have been suggested by these investigators
for monitoring machines and analysis of data.
Hunter Barksdale et al [1] proposed a project for elec-
trical machines with IoT. The author developed an IIoT
for Condition-based Maintenance (CBM) of machines. Their
implementation consisted of temperature sensors and vibra-
tion sensors. Using the sensors, the data is acquired from
machines and analyzed. Also examined in this research are
monitoring of current and voltage profile of the electric
machines to distinguish between working and normally and
machine showing symptoms of a developing fault.
Ali Restegari et al. [2] studied the use of Vibration mon-
itoring of the spindle units. A pilot project was tested at a
gearbox (for the automotive industry) company in Sweden.
C. Lakshmi et al. [3] designed a system Feed pump
condition monitoring using a remote webpage. The used
characteristics that show the robustness of the pump are tem-
perature, vibrations, flowrate, and noise which are observed
in real-time and displayed to the user.
An experiment conducted by Elizabeth Kadiyala et al. [4]
consisted of Raspberry pi, Voltage, and Current sensor with
Zigbee protocol. The measurements were made in real-time
and uploaded to cloud analysis. The proposed project was
used as a test best for the interfacing of sensors such as
temperature, light intensity, water level.
An experimental demo by Sergio M et al. [5] of a smart
box used two cases, based on the communication protocol
implemented: OPC Unified Architecture and Message Queu-
ing Telemetry Transport (MQTT). Both the cases were tested
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by the Author and concluded that MQTT is a good option
since OPC UA servers did not have proper libraries
Alexakos et. al. [6] proposed a new method for the im-
plementation of IoT devices in the industrial process. The
proposed framework can efficiently collect data from the
machine. When an abnormality is detected manufacturing
automation is employed to respond to the issue. In this
work, improvements have been made to past work by moving
intelligence to the edge.
H. S. Raju et. al. [7] proposed layered architecture. The
cloud is used to store services, and dedicated elements
interface with the motor system. The proposed system is
validated on the manufacturing device. The author concluded
IoT can be used for real-time monitoring and can be operated
without any issues.
Jonathan Downey et.al [8], described the European funded
project EU-FP 7 is based on the sensor technology, a case
study is been carried at Schivo Precision an Ireland based
company. It was claimed that there was a huge loss due to
quality production. Out of these rejected parts, about 50%
were because of worn-out tools or broken tools. This case
shows that how using different sensors like Acoustics sensors,
vibration sensors, thermal sensors, force sensors were used to
monitor the tool life of that particular cutting tool.
Sebastian Bombniski et.al [9] proposed a sensor fusion for
data acquisition from CNC machines in realtime, The system
was validated at Schivo Precision, Waterford, Ireland. The
machine is tested with sensors and parameters (Acoustics
emission, cutting force, and vibration) were measured. The
system also implemented an image acquisition system for
checking the wear on the tools after each cycle. The paper
tested the validity in the production environment
X. Y. Zhang et. al. [10] developed a wireless sensor-based
system for condition monitoring. Machine parameters such
as cutting force, power data, and actual machine parameters
to estimate tool life were obtained. The developed system
was verified via machining cases. The authors concluded that
future research can include: analyzing and calibrating the
proposed monitoring system with existing sensors and adding
more data features into the framework to improve its capacity
for data analytics.
Surojit Poddar [11] presented a study to assess the particle
contaminants using Acoustic emission and vibration moni-
toring. The author tested various conditions with different
particle sizes and densities.
The main purpose of Monitoring systems is to detect
patterns in the sensor data and internal signals acquired from
CNC Machines and relate them to possible failure. In the liter-
ature, many investigator have proposed a system with involves
either condition monitoring or availability monitoring but not
both. The major disadvantage is these systems are designed
for specific make or model of CNC machines and there is a
lack of interoperability. This paper presents a prototype that
is fitted to any CNC machines without a major overhaul of
the existing machines. Thus, it is modular and low cost to
implement.
III. SYSTEM ARCHITECTURE
The rapid advancement in the manufacturing technology
and move towards the adoption of information and com-
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 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)
Fig. 1. Conceptual representation of System Architecture of proposed work.
munication technologies on the shop floor, has helped in
actualizing the ”Smart factories” where the machines are
implemented with the IoT system [12].
The system architecture of the proposed work is depicted
in Fig. 1. The system is divided into following 5 layers –
1) Machine Layer – The machine data and parameters are
collected at this layer.
2) IoT Layer – This layer acts as an interface and local
module for connection machines to the internet. It also
does the function of sensor signal conditioning and
amplification.
3) Internet Layer – IoT devices are connected to this layer
and Internet acts as the medium for transmission for
data from the local module to remote server.
4) Data Processing Layer – After data acquisition and
transmission. The IoT data is stored on the server
database for processing and retrievel when required.
5) Management Layer – In this layer based on the an-
alytics and reports generated after processing of data
Management can make decisions on the process.
A. Availability Monitoring
Availability monitoring is done using the internal signals
generated by the CNC machines. The Fig. 2 shows the Data
Acquisition from CNC Machines. These signals are directly
collected from the PLC of the machine. In the proposed
Fig. 2. Data Acquision from CNC Machines
system Raspberry pi 4 along with optocoupler and multiple
sensors is used as IoT and Machine Layer. . The PLC of
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CNC machine is programmed to generate specific binary
signals when an activity occurs(e.g spindle ON/OFF, Alarm,
Clamp/Unclamp). Since the PLC generate 24V Signal an opto
coupler was used to step down it to 5 volts. This optocoupler
gives the added protection of isolation from the machine
circuits. The change in PLC signals continuously monitored
by raspberry pi using Python Code. The calculated Overall
Equipment Efficiency (OEE) is displayed to the supervisor.
To calculate OEE the formula used is -
Run Time = Planned Production Time - Stop Time
Availability = Run Time / Planned Production Time Per-
formance is the ration of (Ideal Cycle Time into Total Count)
by Run Time
Quality = Good Count / Total OEE = Availability *
Performance * Quality
Fig. 3. Hierarchy of Users in Plants
The fig. 3 states the Hierarchy of users in a Plant. It
consists of Plant Head, Manager, Supervisor, and operator
respectively. The role of each user is given below.
1) Plant Head - Plant head has complete access to all
the data analytic reports of all the machines in the
Plant. The Plant head oversee all the daily operations,
division of work between managers and make sure all
the procedures are followed.
2) Manager - The responsibilities of Manager involves
tracking of work progress and analysis of data . They
can develop or make changes to process based on Data
collected by IoT system that can maximize quality and
productivity.
3) Supervisor - Oversee the daily operations on shop floor.
The responsibilities include tasks like creating work
schedules and Monitor nad evaluate the performance
4) Operator - They set up and adjust machines, and mon-
itor them for unusual noises or movements. They exe-
cute the scheduled tasks. Operators ensure the factory’s
equipment functions efficiently and that all procedures
work correctly
An operator dashboard is designed to display the machine
process progress and to take the operator feedback to monitor
downtime. The cloud-based analytics framework is shown in
Fig. 4. The Operator logins using his/her credentials. After
successful login will be redirected to the Operator Dashboard
as shown in Fig. 5.
The operator dashboard show in the Figure 6 has the
following Components
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 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)
Fig. 4. Cloud-based Analytics Framework
Fig. 5. Operator Dashboard
1) Part Selection - The part to be machined is assigned by
the supervisor and the operator before starting should
select from the list of parts.
2) Downtime Timers - Various Downtime timers will
automatically start or stop based on Machine status.
3) Machine Status - The image is used to display the
status, for example, Red - No Machining, Green -
Machining in progress, etc
4) Reason for Delay - If the operator exceeds any timer.
A reason has to be entered in the Form.
5) Progress bar - The number of parts progressed will be
shown here
When Supervisor Logs in the supervisor dashboard is
displayed as shown in Fig. 6, The supervisor dashboard as
the following components
1) Part Running - Displays the Part being manufactured
in Real-Time
2) Parts Produced - The progress for the current part
3) Navigation Menu - Different modules of the System
can be accessed from here.
The supervisor can schedule work to operators using the
scheduling module of the website as shown in Fig. 7. The
Manager/supervisor can also view different downtime reports.
Individual downtime such as Intracycle downtime, Setup
time, alarm, etc is plotted in graphs. Historical values can
also be seen by selecting dates. Scheduling Dashboard is
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Fig. 6. Supervisor Dashboard
Fig. 7. Schdeuling Dashboard
downloaded in PDF or CSV formats. If the operator has
entered any other reason on the operator dashboard, those
reasons will appear in the Downtime reasons section of the
Reports Dashboard.
B. Condition Monitoring
The four main parameters that will be used to monitor the
condition of the machines are:
1) Vibration
2) Temperature
3) Current
4) Coolant level
Manufacturing machines can produce higher quality parts
if the performance degradation due to wear for example spin-
dle units is not quickly known and checked. The wear could
also lead to damage and hence downtime which will lower
the productivity. Monitoring machine condition parameters
such as vibration could help to identify any abnormalities in
the running of machines and maintenance can be scheduled
before a failure occurs.
Research suggests that high temperatures can shorten
motor life in machines. Regularly checking the operating
temperature is critical to prevent unexpected shutdowns and
extending motor life. The proposed system measures the
temperature directly and notify the user if it crosses the
preset threshold. Traditional monitoring of motors usually
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 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)

TABLE I
L IST OF S ENSORS

Sl. No. Sensor Type Description

1. MPU 6050 Accelerometer 3-axis gyroscope and
a 3-axis acceleromete
2. SCT-013 Current Sensor Used measuring alter-
Clamp nating current upto 30
Sensor amperes
3. DS18B20 Temperature Sensor Used for 9-bit to 12-
bit. Measures Tem-
peratures from -55C
to +125C

consists of protection only. Typically, a motor is protected

from overload. By using condition monitoring impending Fig. 9. Message Queuing Telemetry Transport Protocol
failure can be sensed in the device before complete shutdown.
Motor current is shown to the operator in real-time and a
warning is displayed when the current crosses the threshold. with general purpose I/O pins which can be modified as per
The Table 1 lists the sensor used in the proposed system. requirements.
These sensors are used to monitor the machine continuously
in case of any abnormality and visual indication is displayed
on the website.
Cloud Architecture of the proposed system is depicted in
Fig. 8. The Signals acquired from the CNC machines using
Optocoupler and Raspberry Pi.
These signals are then sent to Cloud using MQTT Pro-
tocol for storage in Database. Message Queuing Telemetry
Transport (MQTT) is a publish-subscribe messaging transport
protocol. Fig. 9 represents the MQTT Protocol Architecture.
MQTT has two parts:
1) MQTT broker: MQTT broker is a server that receives
all the messages from the clients and then sends the
messages to the appropriate destination clients.
2) MQTT client: An MQTT client is a device connected
to an MQTT Broker. A device transmitting messages is
called as publisher and device subscribing and receiving Fig. 10. Condition Monitoring Dashboard
messages is called a subscriber.
Once the data is stored into the MySQL database NodeJs The sensors are interfaced to this board and it is connected
is used as An application program interface (API) backend. to internet using WiFi. The Raspberry pi board and the
For the Frontend ReactJs is used to design the user interface. optocouplers are enclosed in a plastic box to protect from
A unique url is used to access the Analytics platform. the environment. The Fig. 10 shows the condition Monitoring
Dashboard. It has the following Components
IV. RESULTS 1) Add Machine - To Add New machine to IoT system
The prototype is mounted on to CNC consisting of Rasp- 2) List - Shows the List of Machines Configured for IoT.
berry pi, Optocoupler. Raspberry pi is an ARM based board 3) Condition - Shows the real-time condition of the ma-
chine i.e Normal / Abnormal / Maintenance required.
4) Productivity - Shows the productivity in real-time.
The selected machine data is displayed in real-time. The
user can configure threshold values and an alert will be
generated based on these values. The Fig. 11 represents the
components of Condition Monitoring detailed view. Fig. 12
shows the screen shot of realtime dashboard for conition
monitoring. At the top of this page the machine name ,
location and the status (Online/Offline) is displayed. The
three gauges indicate Availability, current and temperature.
The current and temperature gauges values are set based on
Real-time readings from sensor and Threshold values. The
graph data of current, temperature and vibration displayed as
shown in Fig. 13 and Fig. 14 is plotted in real time. The
Vibration data is available in both linear and PSD graphs for
Fig. 8. Cloud Architecture analysis.

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 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)

activity ” Section of the web-page. Therefore the operator

can take action before there is damage to the spindle due to
vibration.
TABLE II
S ENSOR DATA

Temperature Vibration
Feed Rate
Sl No. RPM
(mm/rev)
(Celcius) (rms of g)
1. 1000 0.15 33.2 0.228
2. 1500 0.2 35 0.230
3. 2000 0.2 37 0.245
4. 2500 0.2 39 0.395
5. 3000 0.2 41 0.545

The Table II shows the output of the sensors. The graph

Fig. 11. Components of Condition Monitoring detailed view for the same is plotted on the Dashboard. The system was
validated by testing the IoT device on the CNC machine.
The prototype was able to successfully read values from the
machine and display the data in real-time on the dashboard.

V. C ONCLUSION
This work presents a cloud-based analytics framework
for the condition and availability monitoring of ma-
chines.Proposed framework includes the design IIoT hard-
ware and supporting software for monitoring the machining
process by acquiring real-time data of Machine parameters
such as Vibration, Spindle status, Clamp status, Current,
Alarm, Temperature. The hardware is developed in such a
Fig. 12. Real-time dashboard for Conition Monitoring
way that it is plug and play. This avoids major overhaul of
Legacy machines for Upgrading to IIoT. Multiple machines
on the shop floor can be fitted with the system and tracked
in real-time.
The Software developed is stored onto a central Cloud
system which does the functions of storage and analysis of
data. Users with valid credentials only can access the data.
The Integrated UI developed gives an interactive environment
to the user to monitor the key performance indicators (Overall
Equipment Effectiveness) of machines on the shop floor,
thus becoming a useful system for the process of making
Fig. 13. Vibration Sensor Data decisions based on Historical and real-time information trends
of each machine. With the manufacturing sector moving from
industry 3.0 to 4.0 it is imperative for the industries to make
use of all available technologies to minimize downtime and
maximize profit.
Further research can consider issues including implemen-
tation of Machine learning algorithm to predict faults, and
improve security of data transmission and storage.

VI. F UTURE S COPE

Fig. 14. Temperature Sensor Data
The machine reading is taken for 1000RPM, 1500RPM,
2000RPM, 2500RPM, and 3000RPM to verify the remote
fetching of data. The sensor data is shown in Fig. 13 and
There are several modifications and improvements which
could be made to the application developed and Future work
also concerns deeper analysis of the data collected. The thesis
is mainly focused on Process monitoring for minimizing
downtime. The Following ideas could be tested in future
• The data collected from the sensor can be used to train

Fig. 14 respectively. As the RPM of spindle increases the Machine learning models for predictive maintenance.
Vibration detected by the sensor also increased proportionally. • Mobile app can be developed for the supervisor and

The operator or supervisor can set custom threshold values Operators.

for each part being currently machined. Whenever the value Using predictive maintenance and health monitoring of
crosses the custom threshold it is displayed in the “Last machines we can predict the requirement of spare parts and

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 The 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS)

order in time to reduce the downtime due to breakdown of

machines.
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