IoT Enabled Real-Time Availability and Condition Monitoring of CNC Machines

One of the biggest challenges faced by the manufacturing 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. � 2021 IEEE.