Surface roughness is a critical parameter in evaluating the quality, functionality, and performance of machined parts. Accurate and efficient surface roughness measurement directly impacts productivity, cost-effectiveness, and reliability in manufacturing processes. Conventional measurement techniques typically require the workpiece to be removed from the machine tool, resulting in significant downtime and reduced operational efficiency. Additionally, manual measurements are prone to human error and inconsistency. This research presents an innovative integrated wireless tool-holder-mounted surface roughness measurement system utilizing eddy current sensing technology. This system enables real-time assessment directly within CNC machine tools without interrupting machining operations. It incorporates a high-resolution eddy current displacement sensor capable of achieving measurement resolution down to 1 nm. By leveraging the inherent impedance variation principle of eddy current sensing, displacement data are converted into standard surface roughness parameters, including Ra, Rz, Rq, and Rmax. Experimental results demonstrate that, compared to conventional methods, this integrated approach significantly enhances measurement efficiency, reduces downtime, and improves measurement precision. Furthermore, the technology allows for continuous monitoring and immediate feedback, facilitating adaptive machining strategies. Ultimately, the proposed wireless eddy current sensing measurement system provides a robust and feasible solution for achieving fully automated, real-time surface quality monitoring and predictive maintenance within intelligent manufacturing environments.

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Integration of Wireless Tool-Holder Type Eddy Current Sensing for Surface Roughness Measurement in Machine Tools

  • Long-Jun Chiou,
  • Jung-Tang Huang,
  • Chun-Ru Tang

摘要

Surface roughness is a critical parameter in evaluating the quality, functionality, and performance of machined parts. Accurate and efficient surface roughness measurement directly impacts productivity, cost-effectiveness, and reliability in manufacturing processes. Conventional measurement techniques typically require the workpiece to be removed from the machine tool, resulting in significant downtime and reduced operational efficiency. Additionally, manual measurements are prone to human error and inconsistency. This research presents an innovative integrated wireless tool-holder-mounted surface roughness measurement system utilizing eddy current sensing technology. This system enables real-time assessment directly within CNC machine tools without interrupting machining operations. It incorporates a high-resolution eddy current displacement sensor capable of achieving measurement resolution down to 1 nm. By leveraging the inherent impedance variation principle of eddy current sensing, displacement data are converted into standard surface roughness parameters, including Ra, Rz, Rq, and Rmax. Experimental results demonstrate that, compared to conventional methods, this integrated approach significantly enhances measurement efficiency, reduces downtime, and improves measurement precision. Furthermore, the technology allows for continuous monitoring and immediate feedback, facilitating adaptive machining strategies. Ultimately, the proposed wireless eddy current sensing measurement system provides a robust and feasible solution for achieving fully automated, real-time surface quality monitoring and predictive maintenance within intelligent manufacturing environments.