Upgrading the versatility of conventional machine tools using the mechatronic approach

Production managers seek cost-effective methods to meet the basic requirements of a modern manufacturing system, as several conventional machine tools in most manufacturing industries face abandonment or require upgrades due to challenges related to precision and accuracy. This study presents an innovative mechatronic approach that combines three key machine tool parameters: speed, pressure and alignment modules. It integrates them into conventional machine tools as an integrity upgrading enabler through real-time monitoring. A dynamic programming model was used to obtain the integrity and a generated Python software named INTEGMAC, connected seamlessly with Integrity Evaluator 1.0 hardware to analyze real-time attributes of machine tools. INTEGMAC recommends remedial actions, where necessary, to enhance machine tool integrity and was successfully tested on a Boxford 11-30 Industrial Lathe, which improved the electric motor and spindle speeds, offset and angular misalignment, hydraulic and pneumatic pressure readings to meet the manufacturer's benchmark specification. These collective modifications resulted in a significant increase in total integrity from 78.24% to 95.78%. Similar comparable results were obtained from follow-up tests to validate the performance of the developed system. This solution is currently applied in the machine tool industry and can also be extended to other industrial machines.