Integrating sensors into machine components

In reliable production, one gear literally meshes with another. If their teeth or the rolling elements of a bearing are worn, productivity suffers. The fact that machines collect key data on their condition as part of Industry 4.0 is nothing new, but the integration of sensor technology directly into machine components is. Sensor-integrated machine elements (SiME) are an integral building block for comprehensive digitalization.

State of the technology

Common methods for specifically monitoring machine components are, for example, thermal imaging cameras for temperature measurement, intelligent camera systems that monitor the condition based on images or particle analysis in the lubricant. There are also indirect methods, such as monitoring vibrations with sensors on the housing. All of these external methods have the disadvantage that they require special setups due to the distance or the results are less meaningful because they are influenced by external factors.

Technology

Researchers at the Institute of Product Engineering (IPEK) at KIT are integrating the sensors directly into components such as gear wheels, screws or bearings. The sensors are placed as close as possible to the locations where the data is generated (in-situ). The data is then either pre-analyzed in the sensor itself or transferred to the existing IT infrastructure for analysis via common transmission protocols such as Bluetooth or NFC. The aim is to collect sensor data as close to the process as possible without compromising too much on functionality. It is also possible to collect data that cannot be measured remotely, such as deformation, which allows conclusions to be drawn about the force applied to the component. The prototypes already record forces, accelerations or temperatures. It is important to know the function of the component in order to determine the relevant measured variables and implement the sensor technology.

Advantages

The advantages of direct integration are the reliability and accuracy of the results during operation due to the proximity to the component and the resulting elimination of interference factors. Furthermore, the hurdles of sensor integration are reduced as machines can be retrofitted with smart components.

Options for companies

KIT is looking for partners from industry for pilot projects, as well as companies that work together with researchers to develop new, industry-related use cases in order to further develop the technology. This opens up the potential to capture previously unknown conditions in systems.