Product development with sensor integrating machine elements - Managing uncertainty associ-ated to in-situ acquired sensor data in mechatronic systems
Final Report Abstract
The advancing digitalization of our time can be observed in mechanical engineering products and processes alike. From control tasks and condition monitoring to predictive maintenance concepts, digital approaches help and ultimately lead to new customer functions, increased customer satisfaction, generally higher productivity of companies and improved sustainability of products and processes. In order to be able to implement digitalization in mechanical engineering in a targeted manner, condition data on the product or process under consideration in sufficient quality and quantity is required as a cornerstone. Innovative sensor solutions are constantly being developed and implemented in practice to capture this data, with the general aim to place sensors as close to the process as possible – socalled in-situ – in order to keep the uncertainty associated with the measurement to a manageable level. If sensor solutions are placed in a technical system on rotating elements, such as a gearbox shaft, challenges arise with regard to a suitable power supply for the sensor and auxiliary elements as well as the signal transmission from the technical system to the evaluation unit. In the case of sensor integration on rotating elements and the use of sensing design elements, a potential solution is a structure-integrated energy supply and signal transmission via the machine structure. This approach of structure-integrated energy supply and signal transmission, which has not yet been systematically investigated, is the subject of this research project and has been the subject of fundamental research over the past 3.5 years. The project systematically investigates the properties of electrical paths across the structure of a technical system and the influence of disturbance and operating variables on them. The results obtained in the research project allow conclusions to be drawn about the signal transmission behavior of sliding contacts as well as rolling element bearings as a signal transmission element from a rotating to a stationary system and about the signal transmission behavior of helical gears. Statements can also be made about dominant parasitic capacitances in an industrial gearbox as the technical system under consideration. Findings and experiences from the research project can be directly transferred to parallel research projects of the applicant. In addition, interesting further research questions arise, e.g. with regard to the electrical properties of helical gears.
Publications
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DEVELOPMENT OF A GENERAL SENSOR SYSTEM MODEL TO DESCRIBE THE FUNCTIONALITY AND THE UNCERTAINTY OF SENSING MACHINE ELEMENTS. Proceedings of the Design Society, 1, 1243-1252.
Hausmann, Maximilian; Welzbacher, Peter & Kirchner, Eckhard
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Managing the uncertainty in data-acquisition by in situ measurements: a review and evaluation of sensing machine element-approaches in the context of digital twins. International Journal of Product Lifecycle Management, 13(1), 48.
Hausmann, Maximilian; Koch, Yanik & Kirchner, Eckhard
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Methods for In Situ Sensor Integration. Design Methodology for Future Products, 145-163. Springer International Publishing.
Hausmann, Maximilian; Kirchner, Eckhard; Vorwerk-Handing, Gunnar & Welzbacher, Peter
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Sensorische Maschinenelemente sind Bausteine für die Digitalisierung. Konstruktion, 73(09), 28-32.
Kirchner, E.; Geis, J.; Hausmann, M.; Schmitt, F.; Großkurth, D. & Hofmann, K.
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A Procedure Model for the Systematic Sensor Selection and Integration into Technical Systems. Proceedings of the Design Society, 2, 445-454.
Hausmann, M.; Häfner, L. & Kirchner, E.
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Sensory Utilizable Design Elements: Classifications, Applications and Challenges. Applied Mechanics, 3(1), 160-173.
Harder, André; Hausmann, Maximilian; Kraus, Benjamin; Kirchner, Eckhard & Hasse, Alexander
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Analysis of the Electrical Impedance of Graphite and Silver Graphite Carbon Brushes for Use in the Impedance Measurement of Sensory Utilizable Machine Elements. Machines, 11(11), 1009.
Hausmann, Maximilian; Schirra, Tobias & Kirchner, Eckhard
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Analyzing the Electrical Transmission Behaviour of Rolling Element Bearings. 77th STLE Annual Meeting & Exhibition, May 21st – 25th 2023, Long Beach, California, USA, 2023. Präsentation
Hausmann, M.; Liehr, P. & Kirchner, E.
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Investigation of the electrical impedance of the gear mesh of helical gears in an industrial gearbox. 10th International VDI Conference on Gears 2023, September 13th – 15th 2023, Garching, Germany. In: International Conference on Gears 2023, VDI-Berichte 2422, 1173-1179, ISBN 978-3-18-092422-9, 2023. Präsentation, Poster und Proceedings-Beitrag
Hausmann, M. & Kirchner, E.
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Measurement of Electrical Impedance of Graphite and Silver Graphite Carbon Brushes. 2023. Forschungsdaten. Open Access
Hausmann, M.; Schirra, T. & Kirchner, E.
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Systematic approaches for sensor selection and integration – A systematic literature review. Procedia CIRP, 119, 687-692.
Hausmann, Maximilian; Breimann, Richard; Fett, Michel; Kraus, Benjamin; Schmitt, Florian; Welzbacher, Peter & Kirchner, Eckhard
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Systematic identification of disturbance factors on electric characteristics of mechanical gearboxes. Forschung im Ingenieurwesen, 87(1), 399-410.
Becker-Dombrowsky, Florian Michael; Hausmann, Maximilian; Welzbacher, Peter; Harder, André & Kirchner, Eckhard
