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Evolving Connectionist System and Hidden Semi-Markov Model for Learning-Based Tool Wear Monitoring and Remaining Useful Life Prediction

Tool wear can cause dimensional accuracy and poor surface quality in milling process. During the operation of tool wear, it can also cause breakage and damage of the workpieces. To prevent these conditions, it’s important that the tool wear is monitored and the remaining useful life (RUL) is predicted in real time. In this paper, time domain and frequency domain statistical features are firstly extracted using multi-sensory fusion method, including the cutting force, vibration and acoustic emission sensor. Seven eigenvectors are selected as the input of the prediction model based on the distance correlation coefficient between 140 feature vectors and the wear value, which provide the most sensitive features to wear faults. The paper establishes a nonlinear relationship between high-dimensional feature vectors and tools wear based on the evolving connectionist system (ECoS), which uses the incremental learning algorithm to realize real-time prediction of the tools wear. Finally, using the wear value predicted by ECoS as hidden state sequence of Hidden Semi-Markov Model (HSMM), the RUL prediction of the tool based on HMM is established. The 2010 PHM challenge data were used to train the model. The experimental result shows that in comparison with artificial neural network, the ECoS model has higher prediction accuracy, and its mean RMSE error for three tools is 14.8. In comparison with the RUL prediction of HMM model, Probability-based RUL prediction of HSMM is more stable.