A Low-Cost Predictive Maintenance System for CO2 Laser Cutting Machines Based on Multi-Sensor Data and Supervised Machine Learning

This study presents a structured multi-sensor predictive maintenance framework for CO2 laser cutting machines based on real-time data acquisition and supervised machine learning. The proposed architecture integrates heterogeneous sensor signals—including vibration, temperature, humidity, and acoustic measurements—through synchronized feature-level fusion to characterize machine operational states. A statistically grounded thresholding strategy, validated using two years of operational observations and controlled experimental perturbations, is employed to distinguish normal and abnormal behavior. Sensor data are processed using a Decision Tree classifier implemented in Python with Scikit-learn, enabling short-horizon probabilistic fault prediction during operational cycles. The system is deployed in a real industrial environment and validated using cross-validation and structured dataset partitioning to assess generalization performance. Results demonstrate reliable fault discrimination capability under controlled operational conditions, highlighting the effectiveness of feature-level sensor integration for early anomaly detection. The modular hardware–software architecture supports adaptability to other CNC platforms with appropriate recalibration and retraining. The proposed framework provides a low-cost, interpretable, and computationally efficient solution for real-time industrial predictive maintenance applications.