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

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.