Cycle-Informed Triaxial Sensor for Smart and Sustainable Manufacturing

Advances in Industry 4.0 and the emergence of Industry 5.0 are driving the development of intelligent, sustainable manufacturing systems, where embedded sensing and real-time health diagnostics play a critical role. However, implementing robust predictive maintenance in production environments remains challenging due to the variability in machine operations and the lack of access to internal control data. This paper introduces a lightweight, embedded-compatible framework for health status signature extraction based on empirical mode decomposition (EMD), leveraging only data from a single triaxial accelerometer. The core of the proposed method is a cycle-synchronized segmentation strategy that uses accelerometer-derived velocity profiles and cross-correlation to align signals with machining cycles, eliminating the need for controller or encoder access. This ensures process-aware decomposition that preserves the operational context across diverse and dynamic machining conditions to address the inadequate segmentation of unstable process data that often fails to capture the full scope of the process, resulting in misinterpretation. The performance is evaluated on a challenging real-world manufacturing benchmark where the extracted intrinsic mode functions (IMFs) are analyzed in the frequency domain, including quantitative evaluation. As results show, the proposed method shows its effectiveness in detecting subtle degradations, following a low computational footprint, and its suitability for deployment in embedded predictive maintenance systems on brownfield or controller-limited machinery.