System for monitoring machining processes of a computer numerical control machine

A system comprising:

• a machining system configured to perform a machining operation to define a structural feature on a workpiece based on control signals to perform the machining operation, the machining system including:
• a computer numerical control (CNC) machine operable to machine the structural feature on the workpiece;
• a machine controller configured to operate the CNC machine, wherein the machine controller is configured to provide the control signals to the CNC machine during the machining operation;
• and
• a sensor configured to measure an operational characteristic of the CNC machine;
• and
• a machine edge controller disposed external of the machining system and communicably coupled to the machine controller and the sensor, wherein the machine edge controller is configured to perform a learn process to define one or more machining baseline parameters and a machining evaluation during the machining operation of the CNC machine, wherein in executing the learning process, the machining edge controller is configured to:
• acquire learning data indicative of characteristics of the machining system from the machining system during the machining operation for forming the structural feature, wherein the learning data is acquired for multiple cycles of the machining operation,
• generate the one or more machining baseline parameters based on the learning data acquired, wherein the one or more machining baseline parameters define a nominal response of the machining system for performing the machining operation, wherein the one or more machining baseline parameters is provided as a signal profile, a statistical threshold, or a combination thereof;
• and
• associating the one or more machining baseline parameter with contextual data, wherein the contextual data includes data indicative of the machining operation being performed, a tool employed for the machining operation, and the structural feature being formed;
• wherein in executing the machining evaluation subsequent to the learn process, the machine edge controller is configured to:
• acquire data indicative of the operational characteristic of the CNC machine from the sensor, the control signals from the machine controller, or a combination thereof, and
• compare the data with one or more machining baseline parameters associated with the machining operation to determine an abnormal operation of the CNC machine, and
• perform a corrective action in response to the CNC machining system operating abnormally.

A system comprising:

• a machining system configured to perform a plurality of machining operations to define one or more structural features on a workpiece using one or more tools, the machining system including:
• a computer numerical control (CNC) machine operable to machine the one or more structural features on the workpiece based on control signals employed to perform a selected machining operation of the plurality of machining operations;
• a machine controller configured to operate the CNC machine, wherein the machine controller is configured to provide the control signals to the CNC machine during a selected machining operation from among the plurality of machining operations;
• and
• a plurality of sensors configured to measure one or more operational characteristics of the CNC machine;
• and
• a machine edge controller disposed external of the machining system and communicably coupled to the machine controller and the plurality of sensors, wherein the machine edge controller is configured to perform a learn process to define one or more machining baseline parameters and a machining evaluation during the selected machining operation from among the plurality of machining system,
• wherein in executing the learn process, the machine edge controller is configured to:
• acquire learning data indicative of characteristics of the CNC machining system from the CNC machining system during the machining operation for forming the structural feature, wherein the learning data is acquired for multiple cycles of the machining operation,
• generate the one or more machining baseline parameters based on the learning data acquired, wherein the one or more machining baseline parameters define a nominal response of the CNC machining system for performing the machining operation, wherein the one or more machining baseline parameters is provided as a signal profile, a statistical threshold, or a combination thereof;
• and
• associating the one or more machining baseline parameter with contextual data, wherein the contextual data includes data indicative of the machining operation being performed, a tool employed for the machining operation, and the structural feature being formed;
• wherein in executing the machining evaluation subsequent to the learn process, the machine edge controller is configured to:
• acquire data indicative of the one or more operational characteristics of the CNC machine from the plurality of sensors, the control signals from the machine controller, or a combination thereof,
• compare the data with one or more machining baseline parameters associated with the selected machining operation to determine an abnormal operation of the CNC machine, and
• perform a corrective action in response to the CNC machining system operating abnormally.