Predictive Maintenance of Old Grinding Machines Using Machine Learning Techniques

This study aims to develop a predictive maintenance system for an aging vertical grinding machine, operational since 1978, by integrating machine learning techniques, vibration analysis, and fuzzy logic. The research addresses the challenges of increased wear and unexpected failures in older machinery, which can lead to costly downtime and reduced operational efficiency. Vibration and temperature data were collected over 12 days using an MPU-9250 accelerometer, with conditions categorized as good, fair, and faulty. Various machine learning models, including logistic regression, k-nearest neighbors, support vector machines, decision trees, random forest, and Naive Bayes, were trained to classify bearing states. The random forest model achieved the highest accuracy of 94.59%, demonstrating its effectiveness in predicting machine failures. The results highlight the potential of combining multi-dimensional sensor data with advanced analytics to enable early fault detection, minimize downtime, and improve operational efficiency. This approach provides a cost-effective solution for maintaining aging machinery and contributes to both theoretical advancements in machine learning applications and practical improvements in industrial maintenance practices. The study’s findings offer scalable insights for industries reliant on legacy equipment, promoting sustainable manufacturing through optimized resource use and enhanced reliability.