Real time In-Situ Quality Monitoring of Grinding Process using Microtechnology based Sensor Fusion

An innovative approach of non-destructive detection of grinding burn is developed using sensor fusion of an optical sensor and a miniaturized eddy-current sensor, which is realized with a 2D microfabricated planar micro-coil. Additionally, an in-situ cloud-compatible system is proposed for the real-time predictive and preventive monitoring of the workpiece burn in cylindrical grinding process of a hardened 42CrMo4 steel. A reference workpiece, ground with different grinding burn levels, was investigated with the two sensors. The test results show a comprehensive correlation between the process input parameters and the degree of grinding burn on one hand, and the light reflection intensity and impedance response of the micro-coil on the other hand. The test outputs on the reference workpiece are further used for the training of the cloud monitoring system.