arXiv:2412.19950cs.LGcs.RO2024-12被引 6

用单传感器+迁移学习,仅需少量数据就能高精度预测铣削刀具磨损。

Data-driven tool wear prediction in milling, based on a process-integrated single-sensor approach

  • 仅用一个加速度传感器采集数据,通过迁移学习实现跨场景预测。
  • 仅4个刀具数据训练下,ConvNeXt模型准确率达99.1%。
  • 适合工业现场部署,降低数据采集成本,提升维护效率。

精确的刀具磨损预测对维持加工生产率和降低成本至关重要。然而,刀具磨损过程的复杂性给可靠预测带来巨大挑战。本研究探索基于数据驱动的方法,特别是深度学习,在刀具磨损预测中的应用。传统方法通常针对单一工艺,依赖多传感器配置和大量数据生成,限制了在新场景下的泛化能力,且多传感器集成在工业环境中往往不切实际。为此,本研究探讨了使用最少训练数据的预测模型可迁移性,并在两个工艺中验证。同时,采用仅一个加速度传感器的简单设置,建立低成本数据生成方案,通过迁移学习实现模型向其他工艺的泛化。研究评估了多种机器学习模型,包括受Transformer启发的卷积神经网络(ConvNeXt)、长短期记忆网络(LSTM)、支持向量机(SVM)和决策树,训练输入格式涵盖特征向量和短时傅里叶变换(STFT)。模型性能在两台机床上,以及不同训练数据量下进行评估,包括显著减少数据量的场景,揭示其在受限数据条件下的有效性。结果表明,特定模型与配置在有效预测刀具磨损方面具有潜力,有助于发展更灵活、高效的加工预测性维护策略。值得注意的是,ConvNeXt模型在仅使用4个磨钝铣刀数据的情况下,识别工具磨损的准确率达到99.1%。

原文摘要 · Abstract (English)

Accurate tool wear prediction is essential for maintaining productivity and minimizing costs in machining. However, the complex nature of the tool wear process poses significant challenges to achieving reliable predictions. This study explores data-driven methods, in particular deep learning, for tool wear prediction. Traditional data-driven approaches often focus on a single process, relying on multi-sensor setups and extensive data generation, which limits generalization to new settings. Moreover, multi-sensor integration is often impractical in industrial environments. To address these limitations, this research investigates the transferability of predictive models using minimal training data, validated across two processes. Furthermore, it uses a simple setup with a single acceleration sensor to establish a low-cost data generation approach that facilitates the generalization of models to other processes via transfer learning. The study evaluates several machine learning models, including transformer-inspired convolutional neural networks (CNN), long short-term memory networks (LSTM), support vector machines (SVM), and decision trees, trained on different input formats such as feature vectors and short-time Fourier transform (STFT). The performance of the models is evaluated on two machines and on different amounts of training data, including scenarios with significantly reduced datasets, providing insight into their effectiveness under constrained data conditions. The results demonstrate the potential of specific models and configurations for effective tool wear prediction, contributing to the development of more adaptable and efficient predictive maintenance strategies in machining. Notably, the ConvNeXt model has an exceptional performance, achieving 99.1\% accuracy in identifying tool wear using data from only four milling tools operated until they are worn.

刀具磨损迁移学习单传感器预测维护

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