After spindle startup and throughout the machining process, the iKIT-Cube-Solo-Acc, mounted adjacent to the spindle, automatically detects potential chip entanglement on the spindle or the applied toolholder. It promptly alerts the user to initiate a machine stop, thereby mitigating quality risks caused by chip buildup. To validate this, the iKIT-Cube-Solo-Acc was installed at spindle. Equipped with a BT40 toolholder, triaxial vibration signals were acquired at a sampling frequency of 1024 Hz under static conditions, as well as at 1500 rpm and 3000 rpm. Results indicate that vibration is correlated with rotational speed: compared to the static condition, the vibration magnitude increased threefold at 1500 rpm, and surged by nearly a factor of ten at 3000 rpm.

We simulated a chip entanglement scenario and conducted a comparative test at 1500 rpm. Results reveal that the fluctuations of the vibration signals became highly erratic and irregular. Numerically, the Ch2 axis exhibited the most pronounced sensitivity to the rotation effect. A comparison of the FFT spectrum data confirmed that the variation in vibration amplitude along the Ch2 direction was the most prominent.

Our product demonstrates exceptional sensitivity in detecting chip entanglement conditions, with a response latency strictly controlled within 0.1 s, which enables a crucial paradigm shift from passive detection to proactive prediction and real-time control. When chip wrapping occurs, the monitored abnormal fluctuations in vibration signals, coupled with the anomalous amplitude changes in the FFT spectrum, serve as characteristic feature signals to trigger timely machine-stop alerts, directly enhance machining efficiency and prevent material scrap.