Development of a strain sensor for rolling contact loads

Winkelmann, C.; Woitschach, O.; Meyer, Eva-Maria; Lang, Walter

doi:10.1109/transducers.2011.5969179

Cited by 9 publications

(8 citation statements)

References 2 publications

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“…From the literature it was found that aluminum oxide (Al 2 O 3 ) has a thermal expansion co-efficient of 8 × 10 −6 K −1 , similar to steel, and a high mechanical dielectric strength of 9.9-15.8 kV mm −1 . It was also found that sputtered Al 2 O 3 has a very good adhesion to steel (Winkelmann et al, 2011). Due to its good thermal and mechanical properties and good adhesion to steel, it was chosen as the suitable isolation layer.…”

Section: Materials Selectionmentioning

confidence: 99%

Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Sarma¹,

Borchers

Dumstorff³

et al. 2017

J. Sens. Sens. Syst.

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Abstract. This paper presents the results of using a sensor-integrated workpiece for in situ measurement of strain during an outer-diameter cylindrical grinding process. The motivation of this work is to measure in situ process parameters using integrated sensors in a workpiece in order to characterize the manufacturing process. Resistive sensors that operate on the same principle as conventional strain gauges were fabricated on wafers made of steel using standard microtechnology and later the wafers were diced to form unique sensor-integrated steel components (sensor inlays). These inlays are embedded into a groove on the top surface of a cylindrical workpiece using epoxy adhesive. The workpiece is also made of the same steel as the sensor wafers and has similar properties due to a heat treatment process, thereby maintaining the homogeneity of the material over the whole contact area. The sensor-integrated workpiece was used to perform experiments in a Studer S41 highperformance cylindrical grinding machine. The sensor response to the internal strain was recorded during every grinding step starting from a depth of 1 mm down to 2 mm from the top surface. Such an application of sensor integration in materials for in situ process monitoring can be used in other manufacturing processes as well and this can help to observe internal loads (mechanical or thermal) in manufacturing processes.

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Section: Materials Selectionmentioning

confidence: 99%

Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Sarma¹,

Borchers

Dumstorff³

et al. 2017

J. Sens. Sens. Syst.

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“…There are several reasons for this. We would like to mention the most important of these: the need to measure at even smaller spots to limit parasitic influences on the results of a measurement and also to obtain a higher degree of system comprehension [1,2]. In addition, geometrical circumstances like curved surfaces or limited space might prevent the use of conventional sensor designs [3,4].…”

Section: Introductionmentioning

confidence: 99%

Thin-film sensors with small structure size on flat and curved surfaces

Schmaljohann¹,

Hagedorn²,

Buss³

et al. 2012

Meas. Sci. Technol.

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We have developed a fabrication technology for thin-film sensors on metallic substrates with flat and curved surfaces. Physical vapour deposition by means of a magnetron sputtering system is used to deposit an insulating layer and a following functional layer. This layer is structured by distinct photolithographic steps utilizing a self-developed spray coating technique, four-axis robotics with micrometer precision and a UV laser with a spot size below 10 μm. This highly flexible technique allows a rapid change of design to produce various sensor layouts in a short time. Besides the fabrication technology, we present two realized applications for thin-film sensor technology in this paper. First, a tool wear sensor for rotating cutting tools, directly detecting the flank-wear land width, and second, sputtered resistance strain gauges for force measurement. Measurement results showing the potential of thin-film sensors are given briefly.

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“…Under the sponsorship of the scientific center Integrated Solutions in Sensorial Structure Engineering (ISIS), Winkelmann et al (2011) made an approach for a pressure sensor for high-load applications. The sensor was integrated into a conventional bearing washer and used Al 2 O 3 films as isolating layers (Figure 1).…”

Section: Introductionmentioning

confidence: 99%

“…Thereby, the DLC film could act for direct determination of stresses through a piezoresistive effect (Biehl et al, 2006;Peiner et al, 2006;Tibrewala et al, 2006) or as an isolating and a wear resistance covering layer (Nguyen et al, 2009). Under the sponsorship of the scientific center Integrated Solutions in Sensorial Structure Engineering (ISIS), Winkelmann et al (2011) made an approach for a pressure sensor for high-load applications. The sensor was integrated into a conventional bearing washer and used Al 2 O 3 films as isolating layers (Figure 1).…”

Section: Introductionmentioning

confidence: 99%

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Development of hydrogenated amorphous carbon thin film with high electrical resistance for use in embedded sensors in abrasive environment

Decho

Stock

Winkelmann

et al. 2012

Journal of Intelligent Material Systems and Structures

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In this study, a hydrogenated amorphous carbon (a-C:H) film with a high electrical resistance is developed for use in embedded sensors in an abrasive environment. The a-C:H and a-C:H:Si films were deposited by magnetron sputtering. Graphite targets were sputtered by means of bipolar pulsed-direct current power supply and addition of acetylene, argon, and krypton. The a-C:H:Si films were deposited using graphite targets with small silicon inserts. To optimize the adhesion, a chromium nitride interlayer was deposited prior to the carbon layer. The influence of bias voltage, acetylene flow, deposition pressure, and silicon doping on the electric resistance was investigated. Hardness, hydrogen content, and bonding status of the coating were also determined. It was found that the resistance of the film increases with decreasing negative bias voltage and increasing acetylene flow and deposition pressure. With increasing resistivity of the film, the hardness decreases. This was attributed to higher hydrogen contents in these films. The silicon doping of the films has no significant effect on the electrical resistance.

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Development of a strain sensor for rolling contact loads

Cited by 9 publications

References 2 publications

Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Thin-film sensors with small structure size on flat and curved surfaces

Development of hydrogenated amorphous carbon thin film with high electrical resistance for use in embedded sensors in abrasive environment

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