System and method for continuous machine monitoring at a KHz-scale
A device and a method of monitoring a condition of a machine in real time. The method includes: interfacing an edge device with the machine; requesting a handle from a controller of the machine; querying the machine with an adapter of the edge device for a control data; and acquiring control data from one or more sensors of the machine. The method includes repeating the steps of querying the control data and acquiring the control data after a period of time at a high frequency.
1. A method of monitoring a condition of a machine in real time, the method comprising:
interfacing an edge device the machine;
requesting a handle from a controller of the machine;
querying the machine with an adapter of the edge device for a control data;
acquiring the control data from one or more sensors of the machine;
initiating an integrator when the acquired control data indicates a prespecified tool number;
initiating an action to the machine based upon a sum of load measurements from the control data provided by the integrator in response to the sum exceeding a predefined threshold value; and
repeating the steps of querying for the control data and acquiring the control data after a period of time at a high frequency defined by a sampling rate,
wherein during an initial connection period the adapter cycles through a set logic of repeating the steps of querying the machine and acquiring the control data to establish the sampling rate.
2. The method of claim 1 , wherein the sampling rate exceeds 1 KHz.
3. The method of claim 1 , wherein the interfacing comprises connecting the edge device to the controller via an Ethernet port.
4. The method of claim 1 , wherein the querying of the controller further comprises the adapter selecting and implementing components of an application programming interface (API).
5. The method of claim 1 , wherein the acquiring of the control data comprises a first collection thread collecting and formatting the control data on a continuous basis during normal machine operation.
6. The method of claim 1 , wherein the acquiring further comprises one or more additional parallel collection threads establishing supplemental context-setting data items including engaged tool number, part counter, motion commands, and/or general execution status.
7. The method of claim 6 , wherein the supplemental context-setting data items from these parallel threads are synthesized within the adapter and/or served to other programs.
8. The method of claim 1 , further comprising converting the control data to a machine readable format.
9. The method of claim 1 , further comprising altering the set logic of the adapter.
10. The method of claim 1 , wherein the acquiring comprises receiving 16-bit and 32-bit data.
11. The method of claim 1 , wherein the control data is a computer numerically controlled (CNC) machine spindle speed.
12. The method of claim 1 , wherein the acquiring comprises collecting at least one additional data thread selected from a group comprising of modal machine variables, part counter, operational status, and supplemental data items.
13. The method of claim 1 , wherein the acquiring of the control data further comprises measuring a call duration by repeatedly requesting and delivering a number of samples via an application programming interface (API) function call and buffering the control data acquired from the one or more sensors until a duration of the API function call in milliseconds approaches the number of delivered samples.