Sensorless in-process runout monitoring in milling via an industrial edge device

Abstract

Runout in CNC machine tools is a critical factor affecting machining accuracy, surface finish, and tool wear. This article introduces an innovative sensorless approach for monitoring in-process runout during milling. In-process runout is assessed using an industrial edge device that analyzes spindle current and torque signals, which exhibit a strong correlation with dynamometer data. Frequency-domain analysis of the spindle current and torque signals enables sensorless monitoring of runout in real-time. Experimental results on milling of TiAl6V4 demonstrate the potential of this non-intrusive approach for in-process runout detection, offering a cost-effective solution to enhance machining efficiency and precision in smart manufacturing. © 2025 CIRP