Nizhny Novgorod Engineers Create "Smart" Lathe Block with Predictive Diagnostics

At the Nizhny Novgorod State Technical University named after R. E. Alekseev (NSTU), a lathe block with a built-in wireless data transmission system has been developed, capable of predicting machine failure, TASS was informed by the Ministry of Education and Science of the Russian Federation.

The innovative block is equipped with a miniature triaxial accelerometer that registers the slightest vibrations along three mutually perpendicular axes and analyzes the "pulse" of the equipment in real time. The built-in wireless system allows data to be transmitted via Wi‑Fi, radio channel, or Internet of Things protocols, giving engineers the ability to remotely monitor without having to approach the operating machine.

The block's processor automatically measures the level of vibration acceleration, calculates vibration velocity and vibration displacement, and also calculates the root mean square, peak, and instantaneous values of the amplitude. This system allows detecting malfunctions at an early stage and warning about problems long before their critical development. The developers call the device a "cardiograph for a lathe machine."

The introduction of "smart" lathe blocks opens the way for enterprises to predictive maintenance: repair is performed only when necessary, and not according to plan. This reduces downtime, increases tool life, improves product quality due to the stability of the cutting process, and reduces maintenance costs.

The technology demonstrates the prospect of widespread implementation of digital solutions in industrial production, increasing the efficiency and reliability of metalworking equipment.

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