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26 - 28 February 2019 // Nuremberg, Germany

Conferences and supporting programme

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Session 04 - IoT II / IoT Solutions

Predictive Maintenance Using a Fully Compound Material Integrated Measuring System Vortragssprache Englisch

This paper presents the integration of a measurement system which enables predictive maintenance in an industrial environment without the need of external mounted sensors. The main methodology for the predictive wear detection is illustrated by the example of an electromagnetic operated spring pressure brake within an electric drive train. First real world application results are shown within this paper including the smart braking disc. For first practical application, a braking rotor with a corresponding measuring system has been designed. The measurement system consists of an ARM-based processor with integrated wireless interface and inertial sensors. This system is integrated in the friction material itself by using the hot-pressing method. The fabricated encapsulated system will be powered wirelessly over the air within the final application. In order to be able to demonstrate the additional value of the sensors integrated in the material, it was necessary to develop a test bench for the implementation of the methodical development. This serves as a model illustration of the industrial use of the spring pressure brake. The result of the work is the proof of continuous monitoring the safety-critical component brake using the integrated measuring system. The Smart braking disc is equipped with an over-the-air interface (OTA) so the customer can easily change the firmware and define the measurement task on its own without touching the system itself. Various case studies were carried out with the help of the test stand. For this purpose, use cases were defined which allow the methodology to be applied to the field of electromagnetic safety brakes and industrial electric drives. Scenarios such as the detection of the rotation direction and position of the rotor were considered and implemented with the help of MEMS-based sensors embedded inside the friction material. Thus, it is possible to detect and quantify the direction of rotation, angular speed and the position of the rotor without any external sensors. In addition, tasks such as the state monitoring of the rotor-hub connection, were also considered. The results show that it is possible to detect even the smallest possible defects in the gearing with the help of integrated sensors. This means that maintenance can be carried out even if the actual functionality is not yet negatively affected. The measured values can be transmitted wirelessly from the inside of the friction material to a directly accessible base station or with the help of the MQTT protocol to a remote computer. With the help of the microelectronics embedded in the material and suitable algorithms it was possible to demonstrate that a reliable and user-configurable state diagnosis is feasible. No external sensors were used, only the innovative rotor which is already part of the system. These results go beyond the current state of the art in the field of electromagnetic safety brakes and improve the situation for a security related component.

--- Date: 27.02.2018 Time: 2:30 PM - 3:00 PM Location: Conference Counter NCC Ost



Sven Grunwald



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