Online Tool Condition Monitoring Based on Parsimonious Ensemble+

TL;DR

This paper introduces pENsemble+, an online ensemble learning method that adaptively grows and shrinks to monitor tool wear in metal turning processes, reducing complexity and operator effort while handling data streams with concept drift.

Contribution

The paper presents pENsemble+, a novel online ensemble algorithm with adaptive structure and integrated feature selection for real-time tool condition monitoring.

Findings

Low ensemble structural complexity achieved.

Significant reduction in operator labeling effort.

Effective handling of concept drift in manufacturing data.

Abstract

Accurate diagnosis of tool wear in metal turning process remains an open challenge for both scientists and industrial practitioners because of inhomogeneities in workpiece material, nonstationary machining settings to suit production requirements, and nonlinear relations between measured variables and tool wear. Common methodologies for tool condition monitoring still rely on batch approaches which cannot cope with a fast sampling rate of metal cutting process. Furthermore they require a retraining process to be completed from scratch when dealing with a new set of machining parameters. This paper presents an online tool condition monitoring approach based on Parsimonious Ensemble+, pENsemble+. The unique feature of pENsemble+ lies in its highly flexible principle where both ensemble structure and base-classifier structure can automatically grow and shrink on the fly based on the characteristics of data streams. Moreover, the online feature selection scenario is integrated to actively sample relevant input attributes. The paper presents advancement of a newly developed ensemble learning algorithm, pENsemble+, where online active learning scenario is incorporated to reduce operator labelling effort. The ensemble merging scenario is proposed which allows reduction of ensemble complexity while retaining its diversity. Experimental studies utilising real-world manufacturing data streams and comparisons with well known algorithms were carried out. Furthermore, the efficacy of pENsemble was examined using benchmark concept drift data streams. It has been found that pENsemble+ incurs low structural complexity and results in a significant reduction of operator labelling effort.