Concept of a sensor-integrating jaw coupling for measuring operating data

Ewert, Arthur; Menning, Johannes D. M.; Prokopchuk, Artem; Rosenlöcher, Thomas; Henke, E.-F. Markus; Wallmersperger, Thomas; Schlecht, Berthold

doi:10.1007/s10010-024-00748-0

Forsch Ingenieurwes

2024

DOI: 10.1007/s10010-024-00748-0

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Concept of a sensor-integrating jaw coupling for measuring operating data

Arthur Ewert,

Johannes D. M. Menning,

Artem Prokopchuk

et al.

Abstract: In recent years, industry and research (i) have driven the development and application of data-driven machines and systems and (ii) have increasingly introduced predictive maintenance. One of the main challenges is the acquisition of representative data for these applications. In the scope of mechanical systems, machine elements are the key parts for measuring process relevant data. Thereby, elastic couplings offer a considerable potential for a wide range of applications. The present work describes a novel sp… Show more

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2024

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Cited by 3 publications

References 33 publications

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Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

Menning,

Ewert,

Prokopchuk

et al. 2024

Proc Appl Math and Mech

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Shaft misalignments are one of the main causes of damage to couplings in machines. If they are not detected in time, they can lead to machine downtimes. When assembling a machine, however, it is not always possible to align the shafts perfectly. Elastic couplings are able to compensate for such misalignments up to a certain degree. To detect the present radial misalignment, the concept of a sensor‐integrating jaw coupling, developed to determine the transmitted torque, is used. In the teeth of the gear rim, boreholes are drilled and dielectric elastomer sensors (DES) are inserted. If the teeth deform during use of the coupling the DES will deform as well, leading to a change in capacitance, which can be detected. If the two shafts, which the coupling connects, are perfectly aligned to each other, each of the loaded teeth will deform uniformly. However, if there is a radial or angular misalignment, the deformation is different for each tooth, which can be determined with the help of the DES. To demonstrate this effect, a finite element model of the sensor‐integrating jaw coupling with misalignments is created, and numerical simulations are conducted. In this model, the hyper‐viscoelastic material behavior of (i) the gear rim of the jaw coupling and (ii) the DES is taken into account. From the mechanical simulation, the deformed state of the DES is obtained, which is used to compute the capacitance of the sensor. With the results of the numerical simulations, a symbolic regression is performed. The result is an analytical formula that makes the accurate detection of the present radial misalignment possible. The developed framework can later be easily programmed on a microcontroller which is integrated in the sensor‐integrating jaw coupling.

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Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

Menning,

Ewert,

Prokopchuk

et al. 2024

Proc Appl Math and Mech

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Dielectric elastomer sensor integrated in a jaw coupling: Modeling and simulation of mechanical and electrical behavior

Menning,

Prokopchuk,

Ewert

et al. 2024

Journal of Intelligent Material Systems and Structures

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In recent years, the demand for compact and inexpensive sensor systems for the digitalization of production processes has risen. One solution to meet this demand are sensor-integrating machine elements. These are machine elements with integrated sensors, whose geometry is not altered and thus allows an uncomplicated exchange of the conventional machine elements with the sensor-integrating machine elements. In the current work, a numerical model for a sensor-integrating jaw coupling is presented. The aim of the sensor-integration is to determine the deformation of the teeth of the gear rim with dielectric elastomer sensors (DES) and thus draw conclusions about the applied torque. In the following, a model for the DES is presented which is validated with experimental results. It was shown that the experimental and simulation results for the capacitance agree well, if only 50% of the change in area of the electrodes is taken into account. After that, a finite element model for the sensor-integrating jaw coupling itself is presented, which is created with the commercial software ABAQUS. Finally, the advantages and disadvantages for different positions of the sensor inside the gear rim of the jaw coupling are evaluated.

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Experimental investigations and material modeling of an elastomer jaw coupling

Ewert,

Menning,

Prokopchuk

et al. 2024

Materials Testing

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This work investigates the hyper-viscoelastic behavior of a thermoplastic polyurethane IROGRAN A 92 E 5670 FCM used in the gear rim of a jaw coupling. The aim is to provide the material parameters for the modeling of jaw couplings in engineering tasks. Uniaxial compression tests were conducted at various temperatures and loading speeds to fit a hyper-viscoelastic material model. The material model uses the Yeoh free energy and the power law model with one Maxwell element. The parametrized material model showed very good results in comparison to experimental data. In addition, the influence of friction on the experiments was modeled, investigated, and discussed. Further component tests for a jaw coupling of size 28 were conducted with two different specimen types. The original gear rim and a modified gear rim with central boreholes for integrated sensors were used in the test. The influence of such a modification was investigated with four different loading cases, focusing on the torsion-torque characteristic and the relative damping. These component tests enable the validation of numerical models of jaw couplings.

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Concept of a sensor-integrating jaw coupling for measuring operating data

Cited by 3 publications

References 33 publications

Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

Dielectric elastomer sensor integrated in a jaw coupling: Modeling and simulation of mechanical and electrical behavior

Experimental investigations and material modeling of an elastomer jaw coupling

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