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

Thank You

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www.core-sensing.de

Do you have a question for thePresenter? Visit the Guest SpeakersVirtual booth within the next hourfor an interactive Q&A session.