Machining optimization of large casting components by remote monitoring and 3D visualization techniques

Abstract

 The development of the different technologies included in 
the Industry 4.0 paradigm opens the door to an intensive 
monitoring of machine-tools. A data acquisition platform for 
both 2D and 3D analysis of machine performance under real 
factory conditions is presented in this study. The platform is 
composed of: 1) a data acquisition system that processes the 
information collected from the control memory and any other 
sensor integrated in the machine; 2) a remote server that stores 
the collected data; and, 3) a set of 2D and 3D interfaces both 
of which permit real-time calculation of KPIs and analysis 
of a specific machining process in a 3D virtual environment 
using Oculus Rift and Oculus Touch to detect anomalies in the 
machining process. This platform has been validated in a gantry 
milling machine machining large casting components. The 
results of this study demonstrate the detection of three types 
of anomalies in the machining process and the extent to which 
the immersive 3D environment makes it easier for the process 
engineer, especially in the case of junior process engineers, to 
detect them.