AI Software Predicts Machine Tool Drive System Failures

A machine shop’s fear of equipment failure is real and normal. The good news is there are solutions that have been generated in response to pleas for ways to increase machine tool uptime. One automation equipment provider is offering artificial intelligence (AI) software to predict possible mechanical drive system failures when using this company’s servomotors and spindle motors on a machine tool.

FANUC America Corp. offers AI Servo Monitor, an AI software that analyzes daily machine performance and displays the data in easy-to-read graphs on a web interface. The software automatically creates a baseline model of the machine while running in a normal state. If it produces an anomaly score, that expresses a difference in the baseline model and the daily recorded values. So, when this value exceeds the predefined thresholds (abnormal activity), email notifications can be issued to shop maintenance (or a predefined person in the shop) before a failure occurs.

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“The software is ideal for machine shops that run a critical piece of equipment that can be a bottleneck in a production flow, one in which it is extremely important that the equipment has uptime,” explains Rob Taylor, senior account manager in the aftermarket support department at FANUC.

AI Servo Monitor runs on a PC and provides the predictive analytics that works in conjunction with the company’s MT-LINKi machine status monitoring and data collection software. Together, the system is designed for lathes and milling machines equipped with FANUC CNCs. It runs automatically during the day and collects data from the equipment at night, so shop management doesn’t need to think about the monitoring happening in the background, according to Taylor.

“Once AI Servo Monitor is configured, it is just like a set-it-and-forget-it application,” he says. “If an issue occurs, then it will notify the customer. And notification levels can be adjusted by the customer.”

AI Servo Monitor automatically creates a baseline model of the machine while running in a normal state. An anomaly score produced expresses a difference in the baseline model and the daily recorded values. When this value exceeds the predefined thresholds, email notifications can be issued. Photo Credit: FANUC America Corp.

The following seven key points are important to know about the AI Servo Monitor:

1. Shops can choose which machine and motors to monitor. Prior to collecting data, the shop tells the software which machine and motor to monitor by simply using a drop-down menu on the PC interface.
2. No additional sensors required. Because data is obtained directly from the servomotor or spindle motor, a separate sensor is not required. With the help of MT-LINKi, the AI Servo Monitor is monitoring the motor’s speed and torque. The MT-LINKi is monitoring the temperatures of the motor and insulation resistance to ground of the motors, as well as battery statuses and cooling fan statuses of the machine.
3. No need to create a test program. According to Taylor, the existing part program in the machine is all that is necessary to benefit from the software. The software uses machine learning to create anomalies.
4. Most FANUC CNCs are compatible with the software.The AI Servo Monitor software works with most FANUC CNCs and FANUC servos, from the FS16i/18i-B systems and newer, Taylor says. The MT-LINKi software works with all Ethernet-ready FANUC CNCs, as well as non-FANUC CNCs, PLCs and various sensors can be connected using MTConnect or Open Platform Communications United Architecture (OPC-UA) protocol.
5. No external connections to the cloud are necessary. Both AI Servo Monitor and MT-LINKi are solutions that do not require an external connection to the cloud; all collected data remains on-site.
6. The software helps reduce service costs and plan maintenance. Because notifications offered by the system act as predictive maintenance for the machine, the machine shop can potentially save maintenance costs associated with equipment failures; easier and less costly fixes can be made. The AI Servo Monitor also boosts production by enhancing the reliability of the servo and spindle motors and mechanical machine components. The system also makes it simple to schedule critical maintenance on time.
7. Collected data can be analyzed further. Besides the daily anomaly score, Taylor explains that users can drill into the collected data for further analysis, if they wish. “You can also enter comments in the interface to refer back to in the future,” he adds.

FANUC America Corp. | fanucamerica.com