On the potential of low-cost instrumentation for digitalization of legacy machine tools

Smart manufacturing is the convergence of Industry 4.0 technologies that modernize production systems, with a growing demand for real-time active management to maximize processes. Companies with outdated, non-communicative or non-data-transmitting machine tools urgently need new technologies to ensure competitiveness. A viable option is smart retrofitting, which involves upgrading legacy equipment to bring them into the digital age. This article presents a study on the potential of digitizing legacy machine tools to improve productivity and surface quality through low-cost instrumentation. Low-cost sensors and hardware were installed on a universal lathe for continuous and real-time monitoring of the turning process. The results confirmed the influence of cutting speed and feed rate on surface finish, while the instrumentation showed good results in monitoring rotation and feed rate. The results of this paper contributes to recent research in process monitoring and enables a solid analysis of the benefits of real-time monitoring of machining in universal mechanical lathes.

Automated summary

Smart manufacturing is the integration of Industry 4.0 technologies to modernize production systems, requiring real-time management for process optimization. Companies with outdated or non-communicative machine tools need new technologies to stay competitive. Smart retrofitting, which upgrades legacy equipment, is a viable option. This study demonstrates the potential of digitizing legacy machine tools to enhance productivity and surface quality using low-cost sensors and real-time monitoring.