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A novel integration between service-oriented IoT-based monitoring with open architecture of CNC system monitoring

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Abstract

Smart factories are focusing on bridging the gap between physical and cyber-physical systems through software applications. This article proposed an efficient and sufficient data acquisition, storing and processing real-time monitoring information, response, and feedback in milling process monitoring. A methodology to enable integration between service-oriented IoT-based monitoring with interpreted information for open architecture CNC system was presented. The proposed system comprises four main layers: the perception layer, communication layer, application layer, and CNC machine. The developed system was validated through two case studies. First, the developed system successfully enabled data flow through the validation, from CNC machine back to CNC machine. Secondly, the reading of temperature, vibration, and electric current monitoring is higher for the worn cutting tool than the new cutting tool. Third, the percentage difference between new and worn cutting tools for temperature monitoring is up to 3.38%, and for vibration monitoring, it is up to 78.93%. Fourth, the electric current reading is proportional to cutting force as the reading of electric current on cutting insert is higher than reading before cutting tool insert with percentage differences more than 8.33% up to 20%. Based on the findings, it was summarized that the developed integrated monitoring system is feasible enough based on the performance and highly sensitive to any changes that occurred during the machining process, specifically on the cutting tool condition. In the future, this integrated monitoring system could be applied to other open CNC machine-based plug and play.

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Acknowledgements

This work was jointly sponsored by the Centre for Graduate Studies UTHM, Prototype Development Research Grant (Grant code: G011), Ministry of Higher Education, the Malaysian Government under Ministry of Education Malaysia (MOE), Universiti Tun Hussein Onn Malaysia (UTHM), Universiti Teknikal Malaysia Melaka (UTEM), Universiti Teknologi Malaysia (UTM), and Jabatan Pendidikan Politeknik dan Kolej Komuniti (JPPKK).

Funding

This article was partly sponsored by the Centre for Graduate Studies UTHM and supported by the research project grant (Grant code: G011), Prototype Development Research Grant (Grant code: G011), Ministry of Higher Education, the Malaysian Government under Ministry of Education Malaysia (MOE), Universiti Tun Hussein Onn Malaysia and Politeknik Sultan Azlan Shah, Jabatan Pendidikan Politeknik dan Kolej Komuniti (JPPKK).

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Authors and Affiliations

  1. Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, UTHM, 86400, Parit Raja, Batu Pahat, Johor, Malaysia

    Maznah Iliyas Ahmad, Yusri Yusof, Mohammad Sukri Mustapa, Yazid Saif, Anbia Adam & Noor Hatem

  2. Department of Mechanical Engineering, Politeknik Sultan Azlan Shah, 35950 Behrang Stesen, Behrang Perak, Malaysia

    Maznah Iliyas Ahmad

  3. Department of Mechanical Engineering, Politeknik Sultan Salahuddin Abdul Aziz Shah, 40150, Shah Alam, Selangor, Malaysia

    Mohd Elias Daud

  4. Faculty of Mechanical and Manufacturing Engineering Technology, Universiti Teknikal Malaysia Melaka Jalan Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

    Kamran Latif

  5. School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia UTM Skudai, 81310 Skudai, Johor Bahru, Malaysia

    Aini Zuhra Abdul Kadir

  6. Department of Petroleum Engineering College of Engineering, University of Basrah, Basrah, Iran

    Noor Hatem

Authors
  1. Maznah Iliyas Ahmad
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  2. Yusri Yusof
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  3. Mohammad Sukri Mustapa
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  4. Mohd Elias Daud
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  5. Kamran Latif
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  6. Aini Zuhra Abdul Kadir
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  7. Yazid Saif
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  8. Anbia Adam
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  9. Noor Hatem
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Contributions

Maznah Iliyas Ahmad was involved in writing original draft preparation for conceptual, system development, and validation. Yusri Yusof helped in supervision and methodology. Mohammad Sukri Mustapa, Md Elias Daud, Kamran Latif, and Aini Zuhra Abdul Kadir contributed to reviewing and editing. Yazid Saif was involved in conceptual and validation. Anbia Adam and Noor Hatem helped in conceptual.

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Correspondence to Yusri Yusof.

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Iliyas Ahmad, M., Yusof, Y., Mustapa, M.S. et al. A novel integration between service-oriented IoT-based monitoring with open architecture of CNC system monitoring. Int J Adv Manuf Technol 131, 5625–5636 (2024). https://doi.org/10.1007/s00170-022-08675-6

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  • DOI: https://doi.org/10.1007/s00170-022-08675-6

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