Design and implementation of an intelligent grinding assistant system

In modern competitive manufacturing industry, machining processes are expected to deliver products with high accuracy and assured surface integrity, using shorter cycle times with reduced operator intervention and increased flexibility. To meet such demands, the trend towards increased use of machine intelligence in machining systems and operations is clear and unlikely to be revised. This paper describes the structure, content and relations employed in a fully integrated intelligent grinding system for adaptive controlled cycle optimisation, thermal damage avoidance, dressing interval optimisation and data retention. This system, termed: 'Intelligent Grinding Assistant' (IGA) is a unique, robust and versatile software system with embedded links and protocols for communication with the Computer Numerical Control (CNC) and instrumentation of a grinding machine. The IGA was evaluated and implemented on a commercially available production machine and had its international launch in September 2005. The CNC, machine tool instrumentation, process monitoring and data analysis systems, Profibus link, and control strategies all constituted the IGA system. Grinding performance was monitored and assessed in real time. An intelligent database was also developed to support the IGA in the provision of optimised and/or safe starting cycle data to the operator/adaptive system and in the selective retention of data. Importantly, the IGA has been designed and implemented in a way to ensure that an operator can readily use the system and achieve process improvement without recourse to extensive training.