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Machine monitoring system: a decade in review

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Abstract

In recent years, significant advancements have been achieved in the domain of machine monitoring as witnessed from the beginning of the new industrial revolution (IR) known as IR 4.0. This new revolution is characterized by complete automation, and an increase in the technological deployments and advanced devices used by various systems. As a result, considerable advancement has been reported by researchers and academia around the world by adopting and adapting the new technology related to the machine condition monitoring problem. For these reasons, it is important to highlight new findings and approaches in machine condition monitoring based on the wireless sensor solution and machine learning signal processing methodology that are relevant to assist in advancing this new revolution. This article presents a comprehensive review on tool condition monitoring (TCM), tool wear, and chatter based on vibration, cutting force, temperature, surface image, and smart label monitoring parameters from signal acquisition, signal processing methodology, and decision-making, particularly for the milling process. The paper also provides a brief introduction to the manufacturing industries and computer numerical control (CNC) machine tool demand and a review of machine monitoring and countries involvement in machine monitoring, as well as the approaches and a survey of machine monitoring. The aim is to contribute to this rapidly growing field of machine condition monitoring research by exploring the latest research findings on the solution approach for milling machine process monitoring, to help expedite future research, and to give some future direction that needs to be considered as a path to produce a standardized CNC machine platform.

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Funding

This paper was partly sponsored by the Technical and Vocational Education Technology Research Grant Scheme, Prototype Development Research Grant (Grant code: G011), Ministry of Higher Education, the Malaysian Government under the Ministry of Education Malaysia (MOE), Universiti Tun Hussein Onn Malaysia (UTHM), Universiti Teknikal Malaysia Melaka (UTEM), Universiti Teknologi Malaysia (UTM), and Jabatan Pendidikan Politeknik dan Kolej Komuniti (JPPKK).

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Authors and Affiliations

  1. Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, UTHM, 86400, Parit Raja, Batu Pahat, Johor, Malaysia

    Maznah Iliyas Ahmad, Yusri Yusof, Aini Zuhra Abdul Kadir & Yazid Saif

  2. Islamic University of Madinah, Prince Naif bin Abdulaziz, Al Jamiah, Medina, 42351, Saudi Arabia

    Yusri Yusof

  3. Department of Mechanical Engineering, Politeknik Sultan Salahuddin Abdul Aziz Shah, 40150, Shah Alam, Selangor, Malaysia

    Md Elias Daud

  4. Faculty of Mechanical and Manufacturing Engineering Technology, Universiti Teknikal Malaysia Melaka, Jalan Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

    Kamran Latiff

  5. School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, UTM Skudai, 81310 Skudai, Johor Bahru, Malaysia

    Aini Zuhra Abdul Kadir

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  1. Maznah Iliyas Ahmad
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Correspondence to Maznah Iliyas Ahmad.

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Iliyas Ahmad, M., Yusof, Y., Daud, M.E. et al. Machine monitoring system: a decade in review. Int J Adv Manuf Technol 108, 3645–3659 (2020). https://doi.org/10.1007/s00170-020-05620-3

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