Ford Motor Company Limited

Ford Global Technolgoies, LLC

Illinois Tool Works Inc.

Chandra Sekhar Jalluri

Himanshu Rajoria

Prashanth Magadi

Youssef A Hamidieh

Ingrid Margrit Kaufman

Annette Januszczak

David Paul Low

Michael Allen Schmitz

Jon Guske

Evangelos Liasi

Timothy George Beyer

Elizabeth Bullard

Youssef Ziada

Brodie Schultz

Gary Farquhar

James William Perry

John Christopher Pauli

Paul Christopher Shaw

James Pospisil

Mark Goderis

Nimalkumar Sundarakumar

Trevor LeRoi Hill

B Sai Kishore

V Raghavan

Harishankar Rajendran

Loren Gardner

Dan Accetta

Mike Walker

Jasper Blackful

Howard Lee Springston, Jr

Philip Barlas

Moe Lefrancois

Paul Frederick Krotke

Stephen John Hermiller

David P Low

Steven Allen Clinansmith

Craig Felt

David Norman Dilley

Amando Jose Sebastian

A method includes obtaining unprocessed data from a plurality of sensors mounted on one or more plant equipment, normalizing the unprocessed data to generate normalized data, converting the unprocessed data from a time domain to a frequency domain to generate a frequency domain signal, detecting a performance anomaly associated with the one or more plant equipment based on the normalized data and a change index routine, and determining a primary cause from among one or more causes of the performance anomaly based on the frequency domain signal and one or more rules.

Systems and methods for plant equipment condition monitoring

A system includes a computer numerical control (CNC) machining system configured to perform a machining operation to define a feature on a workpiece and a machine edge controller disposed external of the machining system and in communication with the CNC machine system. The machine edge controller is configured to perform a machining evaluation during the machining operation. In executing the machining evaluation, the machine edge controller is configured to acquire data indicative of characteristics of the CNC machining system during the machining operation and compare the data with one or more machining baseline parameters associated with the machining operation to determine an abnormal operation of the CNC machining system. The one or more machining baseline parameters define a nominal response of the CNC machining system for performing the machining operation.

System for monitoring machining processes of a computer numerical control machine

A method of monitoring one or more manufacturing components includes clustering vibration data associated with the one or more manufacturing components to generate a plurality of clusters, determining a vibration characteristic of the one or more manufacturing components based on the plurality of clusters, comparing auxiliary data associated with the one or more manufacturing components and an auxiliary data prediction model associated with the one or more manufacturing components, and determining an auxiliary characteristic of the one or more manufacturing components based on a comparison of the auxiliary data associated and the auxiliary data prediction model. The method includes determining a state of the one or more manufacturing components based on the vibration characteristic and the auxiliary characteristic and broadcasting a notification based on the state.

Predictive maintenance systems and methods of a manufacturing environment

A machine or autonomous system includes a diagnostic controller and is configured to perform a method for monitoring health of a machine. The method includes monitoring a set of first electrical signals indicative of control of a motor of the machine while the machine is operated in a first autonomous mode, determining that an abnormal operating condition has occurred in response to the set of first electrical signals meeting a first criteria, having the machine operate in a test mode in response to the determination that the abnormal operating condition has occurred, monitoring a set of second electrical signals indicative of control of the motor during the test mode, and determining a fault condition in response to the set of second electrical signals meeting a second criteria.

Automation system and wear detection controller

The present disclosure is directed toward a method that includes logging offset data of a machine over a period of operational time having varying thermal conditions, comparing the logged offset data against a thermal model, estimating offsets for the machine based on the comparing, and adjusting offsets of the machine during operation.

Method and system for calibrating and operating a machine

The present disclosure is directed toward a method for monitoring health of a machining tool operable in a machining state to form a workpiece and a non-machining state. The method includes determining whether a machine health routine is to be performed based on a machine health record stored by the control system, and retrieving a non-machining cyclic schedule, in response to the machine health routine having to be performed, where the non-machining cyclic schedule defines a timetable for performing one or more maintenance routines. The method further includes identifying a primary maintenance routine from among the one or more maintenance routines based on the non-machining cyclic schedule, and scheduling the machine health routine with the primary maintenance routine.

Method and system for monitoring machine health to improve machine cycle time impact

The present disclosure is directed toward a diagnostic method for a spindle arm of a machine. The method includes rotating the spindle arm of the machine at a first rotational speed, and acquiring, from an accelerometer, data indicative of a vibrational response of the spindle arm operating at the first rotational speed. The accelerometer is disposed along the spindle arm. The method further includes converting the vibrational response to a frequency based response to obtain a first frequency response, determining whether an amplitude of the first frequency response exceeds a diagnostic threshold, and performing a designated correction on the machine in response to the frequency response exceeding the diagnostic threshold.

System and method for performing a spindle runout diagnostic

A system and method for characterizing surfaces includes using a measuring device to take size measurements of a manufactured product. The raw measurement data is transformed from a time-based domain to a frequency-based domain using a mathematical algorithm. The transformed size measurement data is then compared to predetermined limits within comparable frequency bands to characterize the surface of the manufactured product.

System and method for characterizing surfaces using size data

The present disclosure generally describes a method for processing a workpiece in a machine, where the method determines an offset of the machine and adjusts for the offset during production operation. In one form, the method includes logging offset data of the machine over a period of operational time having varying thermal conditions, and comparing the logged offset data against a thermal model, where the thermal model is generated based on a probing routine and dry cycling for a plurality of test cycles on a calibration artifact. Based on the comparing, the method estimates offsets for the machine and adjusts offsets of the machine during operation.

Method for generating CNC machine offset based on thermal model

In at least one embodiment, a method of analyzing and characterizing the thermal growth of a CNC machine is provided. The method may include mounting an artifact having a bore onto a CNC machine and performing a test cycle. The test cycle may include probing the bore of the artifact to determine its location relative to the CNC machine and performing a dry cycle including one or more CNC machining processes. The method may further include calculating a deviation of the bore location from a reference relative location between the bore and CNC machine. The method may be used to improve, troubleshoot, or assess the effectiveness of CNC machine thermal compensation mechanisms. The method may start at ambient temperature and include repeating test cycles until a steady state temperature is reached in the machine.

CNC machine thermal growth characterization and thermal compensation correction

A tool lubrication delivery monitoring system and a method of control. An accelerometer is provided to detect a position of a valve and fluid flow through the valve. Accelerometer data may be compared to a baseline profile to determine whether fluid flow or valve operation is within established parameters.

Tool lubrication delivery monitoring system and method

A system and method for setting machine limits include setting a limit for a machine parameter, setting a temporal operating range for the machine, and setting a temporal step. The machine is operated over the operating range and the machine parameter is measured. A first new limit for the machine parameter is set based at least in part on the measurements over the operating range. The operating range is advanced by the temporal step, and the machine parameter continues to be measured. Another new limit for the machine parameter is set based at least in part on the measurements over the operating range after the operating range has been advanced.

System and method for setting machine limits

A system and method for monitoring operation of a press assembly includes establishing a baseline vibration level for a first location on the press assembly. The baseline vibration level defines a boundary for vibrations beyond which one or more press elements have a reduced life expectancy. Vibrations are measured at the first location and also at a second location during operation of the press. The vibrations measured at the first location are correlated with the vibrations measured at the second location, and a relationship between the vibrations at the first and second locations is established. Vibrations measured at the second location can then be adjusted and compared to the baseline vibration level to determine if adjustments to the press operation need to be made, or if certain press elements will need to be replaced prior to their expected life span.

System and method for monitoring operation of a press assembly

A method for monitoring health of a machine tool includes operating the machine tool outside an operation cycle to effect movement of a portion of the machine tool. Data from signals output from a sensor and from a controller attached to the machine tool are used to define at least one movement-specific data profile for the movement of the portion of the machine tool. An algorithm is then applied to at least a portion of the at least one movement-specific data profile to generate at least one movement-specific data point. This facilitates generation of at least one movement-specific trend line, which can be used to analysis the health of the machine tool.

System and method for monitoring machine health

A data management and networking system and method are provided for automatically retrieving and storing data from a machine tool for distribution to a remote terminal over a network. Raw data related to a machine operation parameter, such as vibrations, are collected. This data is associated with machining operation data, such as the particular cutting tool being used, or the particular feature being cut by the cutting tool. An algorithm is applied to the raw data to generate a parametric representation of the data, thereby significantly reducing the size of the data. At least some data related to non-machining time is separated out, further reducing the size of the data. The associated data is sent to a network server for storage, where it may be accessed by one or more remote terminals.

Growing community of inventors

Canton, MI, United States of America

Chandra Sekhar Jalluri