A state-of-the-art review on sensors and signal processing systems in mechanical machining processes

Sensors are the main equipment of the data-based enterprises for diagnosis of the health of system. Offering time- or frequency-dependent systemic information provides prognosis with the help of early-warning system using intelligent signal processing systems. Therefore, a chain of data-based information improves the efficiency especially focusing on the determination of remaining useful life of a machine or tool. A broad utilization of sensors in machining processes and artificial intelligence-supported data analysis and signal processing systems are prominent technological tools in the way of Industry 4.0. Therefore, this paper outlines the state of the art of the mentioned systems encountered in the open literature. As a result, existing studies using sensor systems including signal processing facilities in machining processes provide important contribution for error minimization and productivity maximization. However, there is a need for improved adaptive control systems for faster convergence and physical intervention in case of possible problems and failures. On the other hand, sensor fusion is an innovative new technology that makes decisions using multi-sensor information to determine tool status and predict system stability. It is currently not a fully accepted and practiced method. In a nutshell, despite their numerous advantages in terms of efficiency, time saving, and cost, the current situation of sensors used in the industry is not a sufficient level due to the investment cost and its increase with additional signal acquisition hardware and software equipment. Therefore, more studies that can contribute to the literature are needed.

Automated summary

Sensors play a key role in the health diagnosis of system in data-based enterprises, providing prognoses through early-warning systems and improving efficiency by determining the remaining useful life of machines or tools. Sensor fusion, a technology that uses multi-sensor information to make decisions about tool status and system stability, is still not widely accepted or practiced. Despite the advantages of sensors in terms of efficiency, time savings, and cost, there is a need for improved adaptive control systems and more studies contributing to the literature to further enhance their utilization in the industry.