Smart mechanical components with integrated sensors for ...
Transcript of Smart mechanical components with integrated sensors for ...
Smart mechanical components with integrated sensors for IIoT applications MARKUS HESSINGER – CORE SENSING GMBH
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HBK Physical World Conference13 – 15 October 2020
Agenda
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1. Introduction to core sensing GmbH
2. Motivation
3. Challenge
4. Solution
5. Design of integrated sensors
6. Utilization of smart integrated sensors
7. Use case: cardan shaft in roll forming machines
8. Summary
9. Closing
BMWi Funding: Exist Research Transfer in November 2018 Establishment of core sensing GmbH in January 2019 Currently 17 employees and several partners with whom we work on sensory machine parts
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Martin Krech Markus Hessinger Arthur Buchta Simon Krech
Vision: Smart machine components
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Torque
Force
ThrustRPM
Temperature
Acc.
Analyse process and component states Translate data for machine and user
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Challenges ..the size ..the wire ..the distance from the point of action
Goals: Integrating sensors in machine elements, tubes, etc., directly at the point of interest Miniaturized measurement electronics with connectivity Mobile application to measure and configure
Current challenges of sensor integration
A universal sensor element to be integrated in various components
Our solution
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AppVisualization of system status
GatewayConnection to process control
Electronics and softwareSmart event detection,
rpm, acc, temp
Sensor integrationForce and torque
measurement
…and its applications in mechanical industry
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Threaded spindle
Screw conveyor
Cardan shaft
…Couplings
Wireless sensors based on Bluetooth Low Energy App for simple configuration and measuring Up to 4 measuring sensors 500 Hz data rate Strain, acceleration up to 30 g RPM sensor based on sensor signal fusion
Our measurement chain
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2x
Edge device for data processing inside the component
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Occurrence of process fault → On-chip event detection and → Fault message of the gatewayand change of signal display in App coreVIEWER to the process control
In cooperation with a manufacturer, a sensorycardan shaft is made with our product coreIN
Challenge: integration of the sensor before the welding processSensor element is placed 30 mm away from
welding seamSubsequent installation of the batteriesProcess monitoring by the integrated
temperature sensor
Use case: manufacturing of a sensory cardan shaft
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Monitoring of manufacturing step: Sensor integration Welding
Use case: manufacturing of a sensory cardan shaft
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Maximum storage temperature
Welding process
Heat dispersion
In-built temperature sensor on PCB
Time in seconds
Tem
pera
ture
in °C
Manufacturing operation –continuous measuring task
Roll forming = creation of a profile from a flat sheet
Interlinked system with fixed drive ratio
Sensor integration difficult Relevant measuring variables =
Force, Torque No retrofitting solution
Harsh environment, no cables allowed
Exemplary state of the art industrial process: roll forming
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Use case: application of the sensory cardan shafts
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First problem Energy efficiency – individual forming stages work ‘against each
other’. Torques so far unknown
Second Problem 50% of the time the plant is (re-)equipped “Based on a benchmark, Dreistern GmbH & Co KG assumes that
the time required for setting up and adjusting profiling processeswill be reduced by around 50% through the use of assistancesystems.” *
*Dissertation Tilman Traub: Methodik zur Konzeption entscheidungsgestützenderAssistenzsysteme am Beispiel des Walzprofilierens, PtU TU Darmstadt, 2019
Sensory cardan shafts by core sensingfor optimization
coreGATE sends measured datadirectly to the SPS
Pilot plant of the intelligent roll forming machines
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Objective Process monitoring and detection of fluctuations
through data analysis Optimization of energy consumption by optimizing
the drive torques
® Marco Becker, PtU TU Darmstadt, DREISTERN GmbH & Co. KG
® Marco Becker, PtU TU Darmstadt, DREISTERN GmbH & Co. KG
Use Case: application of the sensory cardan shafts
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T Traub and P Groche 2018 : Energy efficient roll forming processes through numerical Simulations in J. Phys.: Conf. Ser. 1063 012182
Dissertation Tilman Traub: Methodikzur KonzeptionentscheidungsgestützenderAssistenzsysteme am Beispiel des Walzprofilierens, PtU TU Darmstadt, 2019
Before optimization After optimization
Results Drive torque per shaft has proven to be particularly suitable for optimizing the drive power Energy saving potential of up to 66% was reached
Usage scenarios
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Drivecontrol
Monitoring ofprocess forces
Lifetimeassessment
Wear detectionOverloadprotection
Gamification
Predictive maintenance
Fitness tracking
HBM service for our sensor elements
Using strain gauges to measure Using OEM service for higher quantities
Together with HBM we can produce sensor elements with high reliability and precision
Fixation of the elements inside the components: core’s core competence
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Summary
Retrofitting of existing production lines with sensor integrated componentsRobust torque measurement inside meachanical partsData analysis and interpretation in edge device
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Integrating sensors in machine elements, tubes etc., directly in the relevant componentsMiniaturized measurement electronics with connectivityMobile application to measure and configure
Growing demand on process monitoring and optimizationDigitalization of production lines
Challenge Solution
Benefit