Int J Adv Manuf Technol (1999) 15:711721

1999 Springer-Verlag London Limited

Commercial Tool Condition Monitoring Systems
K. Jemielniak
Warsaw University of Technology, Institute of Manufacturing Engineering, Warsaw, Poland
One of the most signicant developments in the manufacturing
environment is the increasing use of tool and process monitor-
ing systems. Many different sensor types, coupled with signal
processing technologies are now available, and many sophisti-
cated signal and information processing techniques have been
invented and presented in research papers. However, only a
few have found their way to industrial application. The aim
of this paper is to present the state of the art in commercially
available tool condition monitoring systems and to compare it
to reported research achievements.
Keywords: Industrial application; Tool monitoring
1. Introduction
The quest for process automation is driven by the growing
costs of human labour and quality demands and makes the
monitoring of manufacturing systems inevitable. Therefore,
extensive research work is taking place world-wide in the area
of tool and process condition monitoring, which has been one
of the most important focuses of research effort for more than
twenty years. Numerous papers have been published (see eg.
[13]) presenting many ideas, and many approaches have been
proposed to accomplish tool condition monitoring. In the nature
of scientic research, there is a gap between science and
technology. There is a time lag between research and commer-
cialisation, and any new technology takes time to mature [8].
Some work in this eld can be used in commercially available
systems. Other work is still in the exploratory stages. There
may be several ideas and possibilities for studying certain
phenomena, which all show the potential to become new and
useful commercially protable techniques. However, many of
them will never be applied, as they will prove to be unreliable
or not economic. As actual use in a commercial system is the
nal justication of the applicability of any research work
Correspondence and offprint requests to: Professor K. Jemielniak,
Warsaw University of Technology, Institute of Manufacturing
Engineering, Narbutta 86, 02524 Warsaw, Poland. E-mail:
k.jemielniakwip.pw.edu.p1
concerning tool condition monitoring, reviewing such systems
is worthwhile.
Each tool condition monitoring (TCM) system consists of
(Fig. 1): sensors, signal conditioners/ampliers and a monitor.
The monitor uses a strategy to analyse the signals from the
sensors and to provide reliable detection of tool and process
failures. It can be equipped with some signal visualisation
system and is connected to the machine control. All these
elements will be discussed here. Although there are many
rms offering various tool condition monitoring systems and
equipment, six leading suppliers are considered in this survey:
Artis; Brankamp; Kistler; Montronix; Nordmann and Prometec.
2. Sensors
The sensor is a key element of any tool/process monitoring
system. Although numerous different sensor types have been
invented and applied in laboratories [5], only a few are now
Fig. 1. Example of tool condition monitoring system conguration [34].
712 K. Jemielniak
in commercial use. A summary of sensors applied by different
suppliers is presented in Table 1.
2.1 Power
A power sensor measures the spindle or axis drive power
for a.c., d.c., or variable frequency motors (frequency range
0 200 kHz) [6]. In all suppliers versions (see Table 1) it
measures power directly, using a voltage and current measure-
ment. This sensor is easy to install on both new and existing
machines. The power sensor is installed directly in the electrical
cabinet. The current is measured by 13 Hall effect sensors
[7]. Use of three balanced Hall effect sensors eliminates large
phase shift errors [6]. When two sensors in two phases are
used, the third current quantity results from the two that are
measured, making it possible to take the usual grid uctuation
between three phases into account [8].
Effective power measurement has the advantage over simple
current measurement [9] in that the idle current, which provides
no information about the motor load on the tool, is not
measured [10]. Power is linear, so a change in motor load is
a change in power. Current is not a sensitive indicator of
power at low loads in three-phase motors [6]. The sensor can
provide an indication of a missing tool or tool wear in certain
applications [11]. Using an additional logarithmic signal ampli-
er, small tools can also be monitored [8,10].
If the power-measuring curve is wavy, or displays ripples
or peaks, or even brief (1 s) collapses, the power measuring
value can be smoothed [10]. The quality of effective power
monitoring depends largely on the relationship between the
cutting power and the nominal drive power of the motor. This
means that small tools (such as drills with a diameter of less
than 1 mm) which are individually driven by powerful motors
may be monitored only on good spindle drives see the
example given in Fig. 2 referring to spiral drills in steel or
aluminium under normal cutting conditions [10].
Owing to the inert masses, the output signal has a low-pass
lter characteristic. Therefore, tool breakage is not detected
directly, but only after consequential damage has occurred. A
Table 1. Sensors applied in commercial tool condition monitoring systems.
Physical quantity Suppliers
(sensor type)
Artis Brankamp Kistler Montronix Nordmann Prometec
Force related Power
quantities
Torque
Strain
Distance/displacement
1 3 axis force sensor
Measuring plate
AE Acoustic emission
AE uid sensor
Rotating AE sensor
Others Vibration and ultrasound
Camera
Laser
Fig. 2. Power sensor application range [10].
measurement of the main spindle power often fails to produce
better results, since the spindle power is proportional to the
main cutting force the least wear sensitive parameter [1].
2.2 Torque
Much more accurate tool and process monitoring can be
achieved by measuring mechanical torque directly instead of
measuring the power consumed by the spindle motor. It is
especially useful for tapping and multi-spindle applications
where power monitoring is often not sufcient, as only a small
percentage of the available motor load is used in each cut.
The sensor can monitor tool wear, tool breakage, did-not-cut
condition, thread depth, oversized or undersized pre-drilled
holes, and damaged or missing threads on taps. A torque tool
sensor (TTS) is built especially for tapping in (Fig. 3) [8,12].
It uses strain gauges for torque measurement and non-contact
signal transmission, which consists of a rotor integrated in the
tool shaft and a stator mounted rmly on the machine frame.
The rotor forms a tight ring in the upper part of the tool shaft
or of the clamping chuck and contains the full bridge strain
gauges and the electronics for acquiring and transmitting the
values measured. The stator is installed approximately 5 mm
Commercial Tool Condition Monitoring Systems 713
Fig. 3. Torque tool sensor [8].
away from the rotor and serves both as the transmitter of the
power supply and as the receiver of the measuring signal. TTS
can be used for multi-spindle machines because each tool is
monitored separately.
Montronix has introduced a torque sensor based on magneto-
elastic sensing methods [13]. Accu-Torque has magnetic
properties that are affected by mechanical torque. The sensor
includes a small torque-sensing ring integrated onto the rotating
spindle shaft, and non-rotating pick-up. The ring converts
mechanical shaft torque into a linearly proportional magnetic
eld. The pick-up converts this eld into a linearly proportional
electrical signal and acts as a non-contact means of gathering
shaft torque information.
Excellent rotating quartz 4-component (F
x
, F
y
, F
z
and M
z
)
dynamometers for measuring cutting forces and torque on a
rotating tool spindle are also available [14]. However, because
of their high cost (some $30000) they can be considered only
as laboratory tools for scientic study.
2.3 Strain and Distance
It is relatively easy to retrot various strain and displacement
sensors. Their principal application is indirect force measure-
ment. A quartz strain transducer (Fig. 4(a), [15]) can be
mounted on a part of the machine whose mechanical stressing
is large enough, and as undisturbed as possible.
Transverse (Fig. 4(b) ) and longitudinal measuring pins (Fig.
4(c) ) measure quasi-static and dynamic strains in the structure
of machine components or xtures using the force bypass
principle [15]. The sensors are installed in 510 mm holes.
Owing to the larger measuring range (length of pressure bar)
the axial measuring pin creates a larger measuring signal than
the radial pin [16]. Both sensors are insensitive to force acting
transverse to the chosen axis.
Fig. 4. (a) Strain sensor and (b, c) measuring pins [15].
Fig. 5. RetroBolt [17].
In view of the unavoidable interference and the fact that
these sensors generally possess a low level of sensitivity, they
are normally suitable only for breakage identication during
rough machining [1] and for press force monitoring [15].
The RetroBolt ([17], Fig. 5) is a retrot force sensor typically
used on turret and tool block lathes. This single-axis sensor is
installed as a washer under a bolt head. The bolt selected must
be in the load path. The sensor measures the small changes
in bolt tension resulting from cutting forces exerted on the tool.
Typical monitoring performance using the RetroBolt includes
overload detection, machine protection, and detection of cata-
strophic tool breakage in semi-roughing and roughing appli-
cations.
All force transmitting parts in machines and xtures, such
as housings, spindles, carriages, holders, rods, etc. are deformed
elastically by the forces acting on them, i.e. they are upset,
stretched, bent or twisted. As a result of this deformation, a
detectable displacement occurs between 2 points (reference
point and measuring point, see Fig. 6) on the surface of the
force transmitting parts. Because of high machine rigidity,
the elastic deformations are extremely small. Induction-based
distance sensors are capable of resolving displacements of
as little as 5 nm resulting from forces acting on machine
parts [10,18].
2.4 Force Transducers
One-, two- and three-axis quartz force transducers (Fig. 7(a) )
are load cells with integral cables for use in a hostile machining
environment [15,19]. Design features include rugged, rustproof
714 K. Jemielniak
Fig. 6. Example of distance sensor installation [10].
Fig. 7. Three-axis force transducer [15,19].
housing, electrically ground-isolated mounting faces, and an
armoured cable. They are typically applied in machine tools
in a force shunt (parallel) conguration as opposed to a direct
(serial) conguration. This results in a signicant portion of
the applied load (typically 90% or more) being carried by the
machine structure with only a small percentage (the remaining
10% or less) being carried by the load cell. Thus, effective
load capacities and stiffnesses are ten times, or more, greater
than for the direct conguration. Because of force shunting, it
is extremely unlikely that the load cells will be damaged by an
overload. The load cell installation affects neither the machine
stiffness nor its integrity. The sensitivity of the transducer
depends on the point of force application. Linearity and the
hysteresis of the system are inuenced by installation con-
ditions.
Three main congurations are recommended:
1. Transducer plates (Fig. 7(b) ) are congured as precision
shims to be mounted in a bolted joint in the machine
structure. The plates include one, or two load cells and
must be installed in the cutting force path, typically located
between the turret and the cross-side, or between the Hirth
ring and the turret housing. Transducer plates offer the most
design control and the best performance but are sometimes
difcult to accommodate in existing structures.
2. Pockets provide a less intrusive alternative to plates (Fig.
7(c) ). A load cell is mounted in a precision pocket in a
bolted joint within the machine structure. It is preloaded via
precision tting of an adjustment shim during installation.
3. This alternative is similar to the pocket concept above, but
uses an adjustable wedge to preload the load cell (Fig. 7(d) ).
Special tting requirements are avoided at the expense of
a slightly larger package. Wedges allow the possibility of
Fig. 8. Wireless AE sensor [25].
direct mounting into the machine structure without requiring
a bolted joint.
Although several producers provide such force transducers,
the largest variety (shapes, forms) is offered by Kistler [15].
In fact, some other suppliers also use Kistlers sensors and
measuring pins.
Bearings and bushings equipped with strain gauges for
indirect force measurement [20,21] are no longer in use.
2.5 Acoustic Emission
An acoustic emission (AE) sensor measures the high-frequency
energy signals produced by the cutting process. When a tool
breaks, the sensor also measures the AE energy resulting from
the fracture. An AE sensor is best suited to applications where
the level of background AE signal is low compared to the
sound of tool breakage. This makes the AE sensor ideal for
breakage detection of small drills and taps. This sensor is easy
to install on both new and existing machines. It detects force-
proportional monitoring signals even in machining operations,
which generate very small cutting forces. In combination with
true power, it increases the reliability of breakage monitoring
[8]. It is used especially with solid carbide tools, or very small
tools on large machines and multispindles.
Most of the sensors have to be attached to the machine tool
surface [8,22,23], sometimes with different mounting variants,
e.g. side, top, or bottom connection, and spring disk xing
[24]. However, there are alternative methods of AE wave
transmitting. A rotating, wireless AE sensor consists of a
rotating sensor and a xed receiver [8,10,25] (Fig. 8). It is
suitable for applications where signals from rotating shafts or
translatory components such as slides, pallets, spindles, etc.
have to be passed to a xed receiver for analysis and monitor-
ing. When applied in grinding, the sensor enables precise
detection of any sparking, which enables optimisation of depth
setting [8].
In another approach, an AE sensor receives the acoustic
waves via a jet of cooling lubricant, which can be connected
directly to the tool or workpiece (Fig. 9, [10,26]). Its advantage
over the conventional AE sensor is that it measures close to
the tool. It should be used instead of a conventional AE sensor
when an uneven acoustic transmission caused by variable joints
or interference with the acoustic emissions, could result from
other tools. The uid AE sensor allows detection of high-
frequency stress waves from moving or rotating workpieces or
Commercial Tool Condition Monitoring Systems 715
Fig. 9. Fluid sound sensor [26].
components, or from materials with very rough surfaces. In
some cases the acoustic waves in the coolant stream are
damped so much by the air bubbles that the resulting measure-
ment is too low. Particles of metal and dirt, on the other hand,
do not cause problems. An objective control of the transmission
of the AE via a measuring test is possible using the so-called
lead test. Consistent acoustic impulses can be generated by
breaking the leads of a pencil on the connection surface of
the measuring jet (i.e. on the tool or workpiece).
Although announced a few years ago [19,27], a dual-mode
sensor for the simultaneous measurement of acoustic emission
and one to three orthogonal force components, never reached
the production line. The advantage of this dual-mode sensor
was the backing-up of the force measurement by another
process variable, the acoustic emission, necessitating only one
installation point. However, it appeared that the best place for
the cutting force measurement is usually not the same as the
best for AE measurement.
2.6 Vibration and Ultrasound
A piezoelectric vibration sensor measures the mechanical
vibration of the machine structure resulting from the cutting
process, typically up to 10 kHz [11,28]. It can be used to
detect missing tools, broken tools, out-of-tolerance parts,
machine collision and severe process faults [29]. It is also
possible to monitor excessive vibration on bearings or spindles.
The vibration sensor is easy to install on new or existing
machines.
An ultrasound and vibration sensor (Fig. 10) is suitable for
measuring vibration-induced oscillations up to ultrasonic range
(100 : 80 000 Hz) in machine components [18].
Fig. 10. Ultrasound and vibration sensor and its amplier [51].
2.7 Camera
A camera can be used in the case of multiple spindle heads,
accommodating 20 or more different spindles, when monitoring
each individual spindle is too expensive [8]. The camera
monitors the missing or breakage of individual drills in multiple
spindle heads. During the learning cycle, the camera records
the multispindle head and stores the image. Afterwards, the
head is monitored by a comparison of contours. It can also be
used for all kinds of processes where optical recognition
outperforms a system based on other sensors, e.g. for checking
assembly, tool, location, completeness, spacing or transfer [30].
2.8 Laser
A light barrier offers a reliable tool breakage and tool missing
monitoring system if tools are too small to be monitored by
force, true power, or if there is no suitable place available to
mount an AE sensor [8,10,31]. Cutting edges at a milling
cutter can also be monitored in this manner (Fig. 11). The
edge of the tool is examined with a laser beam with resolution
in the m range. This also allows the measurement of thermal
deformations within machine tools, e.g. the lengthening of the
tool spindles in a machining centre. The high measurement
sensitivity is achieved by a quantitative analysis of the strength
of the laser beam shadowing. The intensity of the laser beam
shadowing is displayed on the tool monitor as a measurement
curve and is monitored within the tolerance ranges. An
Fig. 11. Artis laser used for detection of cutting-edge breakage at a
milling cutter.
716 K. Jemielniak
additional application for the laser sensor is the monitoring of
the roughness of workpieces, chatter marks, or feed marks by
analysing laser light reected from the workpiece. The laser
optics are protected from the spatter of cooling lubricant by
an air barrier.
2.9 Signal Transmission and Conditioning
A common solution in every suppliers system is a separate
signal conditioner/amplier, designed for a specic type of
sensor (e.g. Figure 10). They are robust, vibration resistant,
electrically isolated, and closed in a sealed case. Connecting
cables are shielded with steel braid. So, sensors, connections,
cables and ampliers are very well suited to the harsh environ-
ment in the machine tool in terms of splash protection, moisture
proong, and resistance to aggressive media and to ying chips.
Because force, AE and vibration sensors are piezoelectric
transducers, industrial pre-ampliers convert charge signals
from quartz sensor into proportional voltage signals
(amplication with selectable gain).
An acoustic emission amplier takes the raw signal from
the sensor and provides signal conditioning for enhanced AE
monitoring. By using amplication, ltering, and r.m.s. averag-
ing, the raw AE signal is converted into an AE energy signal
that can be visualised and monitored at lower frequencies. Raw
signal output is applied for diagnostic/service use only. Also
vibration ampliers can be equipped with lters, and r.m.s.
converters [29].
3. The System Conguration
There are two basic congurations of tool and process condition
monitoring systems: compact and modular. Montronix, Brank-
amp, Nordmann, and Kistler produce the former. In such a
system, the core element is the monitor. These monitors are
universal, i.e. they can be fed with signals from different types
of sensor. Signals generated by the sensors and conditioned
by ampliers are send to the monitor, which is directly connec-
ted to the machine control (PLC/CNC). Only Kistler, which is
basically a producer of excellent force, stress, vibration and
AE sensors (used also by some other TCM systems suppliers)
offers one (CoMo II) universal monitor [15,32]. Other pro-
ducers offer at least two solutions simple, economical and
more advanced and expensive. For example Nordmans SEM-
B1 is a one-channel monitor based on a limit set manually or
by the NC-program (only 16 possible levels). It is equipped
with a 16 LED display of the measured value generated by
one of the sensors (AE, active power, force, strain, pressure,
distance) [33]. An alternative is SEM-68000 (see Fig. 1)
which provides up to 16 measuring points or channels, graphic
display, and different monitoring strategies based on limits
(tolerance range, mean height, trend, evaluation of static,
smoothed and dynamic values) [34].
Montronix offers a larger variety of monitors [3539] (Fig.
12):
1. System E: an easy, user-installed monitor for simple transfer
machine applications.
Fig. 12. Monitors offered by Montronix.
2. System Cx/Cz: a monitor for transfer machine application.
TS50: a modular, network-capable two-sensor monitor, uses
limit strategy for collision and tool breakage and tool over-
load detection.
3. TS100: a multisensor monitor for multistation applications.
Uses limit strategy for collision, tool breakage, wear and
overload detection.
4. TS200, TS220: a comprehensive monitor for two- and four-
axis lathes, offered in three congurations:
i Collision only (limit strategy).
ii Collision and breakage (limit pattern recognition).
iii Collision, breakage and wear (limit pattern recognition
wear estimator).
5. TS300: a plug-in monitor for open architecture controls
occupies a single ISA board slot. The ISA bus interface
eliminates the need for either a serial or a parallel I/O
interface. It is based on a 40 MHz RISC processor, which
minimises signal processing and interrupt load on the control
CPU. Any industrial PC can be used as the human
machine interface.
6. PDT: (portable diagnostic tool) a exible monitor for testing
performance on new applications.
A graphic display for Montronix monitors is available only
via the integrated process monitor (IPM) software which
Commercial Tool Condition Monitoring Systems 717
Fig. 13. Examples of monitors offered by Brankamp.
Fig. 14. Modular tool and process monitoring system produced by
Artis.
enables the use of a laptop computer. The IPM graphically
displays the normal machining process and automatically com-
pares it with any abnormal condition. In addition, the IPM can
be used to optimise the monitors protection parameters. The
IPM for open architecture machine controls replaces hardware-
based front panels on monitoring products. It can be congured
so that the IPM display runs in the background, but will
automatically become visible when the monitor generates an
alarm.
Brankamp also produces several monitors, from simple CMS
process control for collision detection, to a 4-channel multi-
sensor, 4 oating limits C 8060 monitoring system [4042]
(Fig. 13). Brankamp has designed this universal process ter-
minal for stamping, cold forming and cutting machines. It is
equipped with a touch screen which is both a colour graphic
display and a keyboard [43].
Modular assembly of tool/process condition monitoring
systems is another concept of systems conguration. It is
represented by the MTC system by Artis [8] and PROMOS
offered by Prometec [44].
A modular tool and process monitoring system (MTC, Fig.
14) consists of a number of sensor dedicated ampliers and
monitoring modules (a separate module for each type of
sensor). They can be operated and their data made visible by
a separate control panel. Another special module enables the
operation of monitoring modules and data visualisation via the
control panel of the machine control. It is also possible to
represent and save machining patterns on a PC with the ViDi
software. MTC can be installed centrally or be decentralised.
With a centralised module arrangement, all the modules are
Fig. 15. Promos modules (examples).
located together in one subrack. This arrangement is used, for
example, for machining centres and lathes because, in these
cases, the points of measurement and the modules are not far
away from one another. With a decentralised arrangement, the
modules are mounted individually near the machines, either on
the station or in the electrical cabinet. The display is arranged
within the operators eld of vision.
PROMOS (the modular process monitor system of Prometec;
Fig. 15) consists of sensors, dedicated sensor modules, univer-
sal monitor modules, machine interface modules, and operator
panel modules. One- or two-channel monitoring modules per-
form their monitoring tasks independently of one another, in
accordance with the specic requirements of the respective
machining stations to which they are assigned. The messages
(breakage, wear, etc.) are transmitted from the monitor module
to the machines programmable controller (PLC) via the
machine interface module. All machine interface modules can
be installed in a switch cabinet. The system can be operated
either via a simple operator panel module OPM12 or via a
much more sophisticated module, equipped with a graphic
display (the OPM20 operator panel module). Other options
are: a PC/notebook; an appropriate human interface panel
module; and the installation of Prometecs operation and visual-
isation software in an open NC control system. A summary
of the visualisation methods applied in TCM systems is
presented in Table 2.
4. Monitoring Strategy
An analogue (electrical) signal from the sensor is usually (after
basic signal conditioning, e.g. primary ltering) converted to
a digital form. The time series obtained is then processed to
extract signal features that are sensitive to the parameters of
interest in the monitored process. The detection of process
irregularities is achieved by the implementation of some sensing
methodology, called a monitoring strategy. Monitoring stra-
tegies applied by different suppliers can be grouped into six
approaches, summarised in Table 3. Most of them are based
on static (remaining xed during the processing of the current
workpiece) limits.
718 K. Jemielniak
Table 2. Visualisation methods applied in TCM systems.
Visualisation method Supplier
Artis Brankamp Kistler Montronix Nordmann Prometec
Simple digital/bar display
Graphic display
Via open CNC control system
Via PC/notebook
Table 3. Strategies applied in TCM systems.
Strategy Artis Brankamp Kistler Montronix Nordmann Prometec
Static limits Simple xed limits
Time dened limits
Part signature
Pattern recognition
Wear estimator
Dynamic limits
4.1 Simple Fixed Limits
The simplest strategy is based on xed limits, which apply to
the raw, ltered, averaged signals or the area under the curve.
During machining of the rst workpiece, the monitor signal is
calibrated automatically (normalised to 100%) cycle-by-cycle
for each cut or each tool by means of the teach-in process (or
via manual calibration) and the positions of limits relative to
this standard are dened. A typical example of it is the strategy
implemented in monitors TS50 and TS100 [36,38]. Limits are
(Fig. 16):
1. L1: Fast acting upper limit typically set at the maximum
allowable range for the machine. Stops machine immediately
for a machine-threatening event (collision).
Fig. 16. (a) Fixed and (b) oating limits.
2. L2: Fast acting upper limit set a multiple (e.g. 250%) of
the maximum learned signal for each tool. Stops machine
immediately for a major tool fracture.
3. L3: (TS100 only) Slow acting upper limit set at a multiple
(e.g. 150%) of the maximum learned signal for each tool.
Stops machine, or inhibits the next cycle, when the process
is out of the allowable range owing to worn tool.
4. L4: Lower limit set at a multiple (e.g. 50%) of the maximum
learned signal for each tool. Used to detect a missing tool
and inhibit future cycles.
Instead of xed limits L1 and L4, oating limits can be
applied. They track cycle-to-cycle trends by using information
from the current cycle to adjust the limits used for the next
cycle automatically [45]. Missing-tool detection, for example
in multispindle applications, may be improved using this tech-
nique. Floating limits are also more sensitive to short-term
rapid events than xed limits.
Similar strategies, based on static xed limits, are used in
PROMOS [44] and SEM-B1 [33].
4.2 Time Dened limits
Fixed limits can be time-displaced, and thus can be better
adjusted to real monitored processes than simple xed limits.
They monitor one or more subareas of a signal progression.
The widest variety of time-dened limits is used in Nordmanns
strategy [34]. Examples are given in Fig. 17:
1(a) For sudden heavy tool wear detection.
1(b) Triggers an alarm when the workpiece is cut too
early.
2 Stops the machine immediately when triggered owing
to tool fracture, run out of machined part or wrong
adjustment.
Commercial Tool Condition Monitoring Systems 719
Fig. 17. Some of time dened limits used in Nordmanns strategy [34].
3 As 2, however, stops the machine only when it is
crossed, but not when measured curve runs com-
pletely undemeath it.
4(a)4(c) Must be crossed at least once to detect the cutting
of a workpiece, to test tool presence at the end of
a cut, and for self-checking of the correct acoustic
coupling of the lubricant.
5(a) Triggers an alarm at the end of a cut when the mean
height of the curve, calculated during a chosen period
of time, reaches it owing to tool wear when cutting
force sensor is used.
6 Triggers an alarm at the end of a cut when the mean
height drops down to its value owing to tool wear,
as some tools become quieter with increasing wear.
The rising through and falling through limits used in
Prometec strategy are similar to 4a and 4b described above
[44].
Kistlers box function monitors whether the signal pro-
gression enters or leaves through the prescribed side of the
box [32]. The remaining sides must not be touched. It can
also be used to control the stop position of a process.
4.3 Part Signature
The cutting process is divided into segments using stepped
limits based on time or position, with a particular set of limits
for each individual segment. It creates a part signature, which
can more closely track a complex cutting cycle than a single
set of xed limits [45]. Stepped limits can be used as time-
dened limits described above, or can create oating reference
limits surrounding measurement curves like a tight tube (Fig.
18). All suppliers but Prometec use this strategy at least in
some of their monitors.
Fig. 18. Part signature visible on Brankamps monitor screen [41].
Timing between the stepped limits and the current cycle is
critical for maintaining performance and avoiding missed or
false alarms [45].
4.4 Pattern Recognition
Montronix developed a tool-breakage detection strategy based
on pattern recognition, available only on the TS200 series (for
turning) [45,46]. The system stores a number of reference force
shapes or patterns that are indicative of tool breakage (Fig.
19), e.g. when carbide breakage cutting force suddenly rises
for a while, then drops to zero. When a ceramic tool breaks,
the cutting force drops to zero. Patterns are also stored for
chipping and interrupted cuts. The system continuously moni-
tors the signal for one of the break patterns. If one or more
patterns are identied, a break is declared within 10 ms of the
breakage. Break detection through pattern recognition has the
advantage of being independent of the magnitude of the process
signal value. The monitor can, therefore, be optimised to ignore
process changes that are not related to tool condition, such as
material dimension, feedrate, interrupted cuts, and part hard-
ness.
4.5 Wear Estimator
The wear estimator is another proprietary technique developed
by Montronix used for turning tool ank wear estimation
[45,46]. The method uses the relationship between all three
cutting force components, and, therefore requires a three-axis
force sensor. It enables normal tool wear, which primarily
affects passive and feed forces, to be distinguished from process
variations such as workpiece runout and variations in workpiece
hardness, which can adversely affect systems using simple
threshold or signature techniques. Generally, a wom tool is
not a catastrophic event and when detected it is usually possible
to continue machining to the end of the current operation.
4.6 Dynamic Limits
Prometecs PROMOS system incorporates dynamic limits for
tool-breakage detection (Fig. 20) [44]. The two dynamic limits
Fig. 19. Pattern recognition for breakage detection [45,46].
720 K. Jemielniak
Fig. 20. Dynamic limit strategy of Prometec.
above and below the monitor signal follow the monitor signal
continuously for every load level at a limited adoption speed
(not to be confused with a signal pattern or a signal tube). In
the case of an extremely fast crossing of one of two dynamic
limits, they are frozen (rendered static) and total breakage,
breakage, chipping, workpiece cavity, hard cut interruption,
etc. are distinguished from one another via visual comparison
with the monitor signal. Slow but large load changes due to
variations in cutting depth (hardness, oversize, out-of-roundness
of workpiece), such as occur during initial cuts, in particular
when machining cast and forged parts, are tolerated at a ratio
up to 1:4.
Another version of Prometecs dynamic limit is presented
in Fig. 21. Instead of the direct force signal, a special feature
signal is processed from the sensor signal [47,48]. This feature
Fig. 21. Prometecs dynamic limit strategy for milling.
is optimised to enhance breakage-specic signal components.
The signal is also automatically used to cope with the wide
difference in force or signal values produced, for example, by
large roughing tools as compared to small nishing tools.
Signal adaptation automatically keeps signals at an optimum
level for analysis. The combination of feature conditioning,
automatic signal adaptation and dynamic limits means that
monitoring functions are fully automated over a wide range of
force or sensor signals in completely different machining situ-
ations, without manual adjustments or a teach-in phase. Tool
breakages are detected practically at the instant of breakage
(typically 5 ms), by means of typical changes in the sensor
signal.
5. Conclusions
Most commonly used, in tool condition monitoring systems,
are sensors measuring cutting force components or quantities
related to cutting force (power, torque, distance/displacement
and strain). They are relatively easy to install in existing or
new machines, and do not inuence machine integrity and
stiffness. All systems suppliers also use acoustic emission
sensors, especially for monitoring small tools and for grinding.
Some applications use vibration sensors and optical systems
(laser, camera). All sensors used in TCM systems are well
adjusted to harsh machine tool environments.
Despite much research work concerning advanced signal
analysis (e.g. FFT, cepstrum, ARMA, statistical analysis), the
dominant signal processing technique is ltering (low-pass,
high-pass and band-pass), averaging and r.m.s.
Since constant (at least during processing current workpiece)
limits only work when all restrictions (depth of cut, workpiece
material, etc.) remain constant, the use of more elastic, self-
adjusting limits is more appropriate in most cases [1,20].
However, only Prometec in dynamic limits and Montronix
in wear estimator and pattern recognition strategies use
more sophisticated signal processing.
Monitoring systems developed in laboratories, are often
multisensor systems embodying complex AI-based strategies to
integrate information, extract features and make more reliable
Commercial Tool Condition Monitoring Systems 721
decisions on the state of the tool and process [1,3,49]. In
commercially available systems, the one sensor one
tool/process approach dominates. Multisensor here means pro-
viding the best sensor for each application. Sometimes using
two different sensors for one process is recommended for the
multiple detection capability of the system. However even then
the signal processing and detection techniques applied to each
sensor are primarily independent [50]. Only the Montronix
wear estimator strategy uses more than one signal for moni-
toring the wear of one tool (exclusively for turning).
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