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Sensors 2016, 16(3), 269; doi:10.3390/s16030269

An Attachable Electromagnetic Energy Harvester Driven Wireless Sensing System Demonstrating Milling-Processes and Cutter-Wear/Breakage-Condition Monitoring

1
Department of Mechanical Engineering, National Chiao Tung University, Hsinchu 30010, Taiwan
2
International College of Semiconductor Technology, National Chiao Tung University, Hsinchu 30010, Taiwan
3
Precision Machinery Research Development Center, Taichung 40768, Taiwan
*
Author to whom correspondence should be addressed.
Academic Editor: Jianmin Miao
Received: 23 August 2015 / Revised: 5 December 2015 / Accepted: 7 January 2016 / Published: 23 February 2016
(This article belongs to the Section Physical Sensors)
View Full-Text   |   Download PDF [3533 KB, uploaded 23 February 2016]   |  

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. View Full-Text
Keywords: attachable; energy harvester; electromagnetic; wireless; vibration; sensing; milling monitoring; cutter condition; self-powered attachable; energy harvester; electromagnetic; wireless; vibration; sensing; milling monitoring; cutter condition; self-powered
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Chung, T.-K.; Yeh, P.-C.; Lee, H.; Lin, C.-M.; Tseng, C.-Y.; Lo, W.-T.; Wang, C.-M.; Wang, W.-C.; Tu, C.-J.; Tasi, P.-Y.; Chang, J.-W. An Attachable Electromagnetic Energy Harvester Driven Wireless Sensing System Demonstrating Milling-Processes and Cutter-Wear/Breakage-Condition Monitoring. Sensors 2016, 16, 269.

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