Control-System-Based Approach for Robust Process Monitoring in Single Item Production

Process monitoring systems are used in production processes to identify disturbances. Until now, they are primarily used in mass production. This paper presents a new teach-less monitoring approach for milling processes. The algorithm is based on measured drive- and control-inherent signals of a machine tool. In order to guarantee a robust strategy the engagement of the tool and the machine conditions were taken into account. For this purpose model-based approaches were realized. The evaluation of actual data in a material removal simulation leads to a perfect synchronisation between simulation and measured drive-and control-inherent signals.