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Frequent tool changes due to wear and tear and the associated downtime not only lead to quality losses in parts manufacturing, but also increase production time and costs. This affects the entire spectrum of mechanical processing on the market, from large-scale industry, such as the automotive industry, to small contract manufacturing companies.

The use of innovative process and condition monitoring systems is intended to prevent such failures in the future and optimise tool life.

The aim is to analyse existing sources of error in the ongoing process in order to precisely determine the condition of the tool, e.g. when turning or milling metal, to control machines in a resource-efficient manner and to ensure a high level of machining quality for components.

Based on the experience that specialists in the field of machining often use acoustic signals or subjectively perceived acoustic stimuli to detect possible process changes and disturbances, AI-based acoustic monitoring is to enable reliable detection of wear conditions in milling tools in real time, directly on the tool and during the ongoing process, without the need for additional sensors.

The aim of the Fräsamo research project is therefore to develop a new generation of intelligent real-time monitoring systems for machining technology by combining acoustic signal processing and artificial intelligence to reliably detect wear conditions of milling tools without additional sensor technology directly on the tool and during the running process.

The involvement of EU funding underlines the relevance of the project for European industry and the strategic importance of the further development of Industry 4.0 technologies.

Key details:

 Technology: The acoustic signals generated during the milling process are analysed.

• Project partners: Among others, the Fraunhofer Institute for Digital Media Technology IDMT and the Technical University of Ilmenau.
• Objectives: Acoustic monitoring is intended to achieve the following benefits:

o    Fewer production downtimes.

o    Optimised maintenance intervals.

o    Longer tool life.

o    Higher efficiency in production.

• Contribution to industry: The project contributes to Industry 4.0 and creates new opportunities for predictive maintenance.

Responsibilities of Microtech Gefell GmbH

Development of protective caps for measuring microphones for difficult inline production conditions.

Project duration:  January 2025 – December 2027

Joint theme: Timely wear detection to optimise the tool life

Funding institutions:

The project, funded by the Free State of Thuringia was supported by funds from the European Union, the European Regional Development Fund (ERDF).