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SOLUTION

Industry Solutions

Solution of Machine Tool Fault Prediction

Problems In Machine Tool equipment

In the industrial machine tool industry, the industrial chain is mainly composed of upstream raw materials, midstream various machine tool products and downstream application services. In this industry, the operation of various functions of machine tools and the completed operations are key factors in the production process. Therefore, in the stage of innovation and upgrading of our country's machine tool industry, machine tool manufacturers hope to improve the efficiency of after-sales operation and maintenance, reduce maintenance costs, ensure the market application performance of their products, and predict the health of customer on-site machine tools. End users hope to avoid the loss of production line shutdown due to abnormal machine tool equipment, understand the operating health of machine tool equipment in real time, effectively carry out inspection and maintenance of machine tool equipment, and shorten the troubleshooting time.

Solution Value

According to the problems encountered in the machine tool industry, Witium launched the "machine tool fault prediction system solution", which collects and monitors the cutting tools, motors, reducers and other units in the machine tool equipment, obtains the health status of the equipment, forecasts and alarms, forms the health diagnosis report of the machine tool equipment sub units, and gives maintenance suggestions. This set of fault prediction system solutions can bring great business value to users:

Solution Details

Solution Architecture

  The machine tool fault prediction solution uses the Internet of things high-frequency vibration sensor to collect the vibration waveform samples and surface temperature of machine tool equipment, and generate the vibration characteristic samples of machine tool tools and other units; The edge computing gateway collects the three-phase winding temperature and lubricating oil temperature of the machine tool through the platinum resistance to understand the operating load state of the machine tool equipment. Combined with the vibration characteristics of the sensor, the intelligent mechanism model algorithm is used to analyze the big data of the sampled data, and the roughness is detected according to the product indication, so as to realize the gradual deterioration in the cutting process of the equipment, such as tool wear, plastic deformation Fault prediction and diagnosis of poor cutting and vibration intensification; Then upload the data samples and analysis learning results to the witcloud Internet of things data cloud platform through mqtt; The SaaS business cloud platform of the solution provides users with status monitoring, scene monitoring, fault management, operation and maintenance management, equipment management, customer management, authority management and other functions; It also provides data interface function to facilitate users to import equipment status into intelligent factory operation and maintenance platform system. At the same time, the business cloud platform provides professional users with operation status analysis and early warning fault analysis of machine tools and equipment through big data analysis tools, and forms professional machine tool equipment health diagnosis reports and maintenance suggestions.

Solution Software

Solution Web Side Software Diagram

Solution Mobile Software Diagram

Solution Hardware

High frequency vibration sensor

MEMS vibration sensor
Medium and high frequency vibration monitoring
The sampling frequency is up to 20khz
Magnetic suction easy installation

RS485
WTS4VXX

USB
WTS6VXX

BASIC PARAMETER
  • Power Input
    DC4.5V-5.5V
  • Low power function
    support
  • Work Temperature
    -40 ℃-105 ℃
  • Work Humidity
    10%-95%(No condensation)
  • IP Rate
    IP67
  • Installation
    Threaded fixing / magnet fixing
  • Overall dimension
    40*40*15mm/40*40*19mm
  • COM Interface
    RS485/USB
  • COM Protocol
    Modbus-RTU
  • Shell Materials
    Aluminum
TEMPERATURE
SENSOR
  • Temperature Object
    Interface temp
  • Temperature Range
    -40°C~105°C
  • Resolving power
    ±1°C
VIBRATION SENSOR
  • Acceleration(G)
    3 Axis:±8g
  • Sample Duration
    1S/10S
  • Frequency
    4KHz/20KHz
  • Axis
    3 Axis
  • Acquisition accuracy
    1mg/LSB
  • Data Content
    Real-time vibration wave/ Characteristic Value

Edge computing gateway

Edge AI Calculation
Several vibrating channels
Multiple wireless Transmit
Embedded algorithm model

WTG9XXW

WTG9XXF

WIRELESS COMMUNICATION
PARAMETER
  • Communication
    WiFi
    4G(Cat1)
  • Mbps
    3Mbps

    upstream 5Mbps/
    down 10Mbps

  • Work Method
    Sta mode / AP configuration
    -
  • DTE-DTE
    40M
    -
  • communication channel
    802.11b/g/n
    LTE-TDD:B38/B39/B40/B41
MAIN PARAMETER
  • Number of vibration channels
    1-6 Optional Channels
  • Vibration interface
    RS485(ModBus-RTU)
  • Oil Temperature
    1 Pt100 Breakage Detection
  • Three winding temperature
    3 Pt100 Breakage Detection
  • LED
    1 * power light, 1 * sensor communication light, 1 * network status light
  • Firmware update
    Online update, remote update
BASIC PARAMETER
  • Shell Materials
    Industrial plastic shell
  • Overall dimension
    115*70*47mm
  • Installation
    Industrial guide rail / strong magnetic fixing / flange fastening / Strap
  • Power Input
    85-262VAC/12-36VDC
  • Operating temperature
    -30~70°C
  • Storage temperature
    -40~85°C
  • Protection
    Overload protection / output short circuit protection / overheating protection
  • Waterproof grade
    IP67

Solution Hardware Diagram

Site Map Of Successful Cases

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Copyright: Shanghai Witium Information Technology Co., Ltd
Website records: Shanghai ICP 19015228-1
Police record number: 31011202009248