Requirements for Sensor Integrating Machine Elements : A Review of Wear and Vibration Characteristics of Gears

Peters, Julian; Ott, Lorenz; Gwosch, Thomas; Matthiesen, Sven

doi:10.5445/ir/1000127139

Cited by 3 publications

(4 citation statements)

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“…A first attempt to define a new gear body geometry has been to adopt the annular board, as proposed in [36][37][38][39]. Figure 3 shows two geometries which have been designed considering an annular sensor with a 10 mm width.…”

Section: Definition Of the Gear Body Shapementioning

confidence: 99%

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The Effect of Sensor Integration on the Load Carrying Capacity of Gears

et al. 2022

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Classical machine elements have been around for centuries, even millennia. However, the current advancement in Structural Health Monitoring (SHM), together with Condition Monitoring (CM), requires that machine elements should be upgraded from a not-simple object to an intelligent object, able to provide information about its working conditions to its surroundings, especially its health. However, the integration of electronics in a mechanical component may lead to a reduction in its load capacity since the component may need to be modified in order to accommodate them. This paper describes a case study, where, differently from other cases present in the literature, sensor integration has been developed under the gear teeth of an actual case-hardened helical gear pair to be used within an actual gearbox. This article has two different purposes. On the one hand, it aims to investigate the effect that component-level SHM/CM has on the gear load carrying capacity. On the other hand, it also aims to be of inspiration to the reader who wants to undertake the challenges of designing a sensor-integrated gear.

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Section: Definition Of the Gear Body Shapementioning

confidence: 99%

“…As a matter of fact, the idea of a smart gear has recently been proven to be a promising and feasible idea by Peters, J. [36][37][38] and by Sridhar, V. [39]. However, their studies were based on a spur gear geometry in an "open" gearbox (i.e., without housing), and the sensor board was directly attached to the gear body.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Sensor Integration on the Load Carrying Capacity of Gears

et al. 2022

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“…In recent years, attention has shifted from ordinary machine elements to sensor-integrated machine elements [4,5]. Examples of the first approaches of sensor-integrated machine element are a sensor-integrated gear, published by Bonaiti et al [6] and prototypes of smart couplings proposed by Schork et al [7].…”

Section: Introductionmentioning

confidence: 99%

“…The task of integrating the sensor into the jaw coupling involves many steps. In order to reduce the complexity, we present a substitute system which focuses on the sensor part of the sensor-integrated machine element [5]. In order to achieve this, the complex geometry of a tooth of the gear rim, made of thermoplastic polyurethane (TPU), is simplified as a cylindrical specimen.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing of soft capacitive strain sensor based on dielectric elastomer material for an elastic element of a jaw coupling

Prokopchuk,

Ewert,

Menning

et al. 2024

Eng. Res. Express

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In this work, we present a procedure for manufacturing a soft capacitive strain sensor in the form of a multi-layer electrical capacitor for further integration into the elastic gear rim of a jaw coupling. The dielectric elastomer sensor (DES) is based on an elastomeric substrate with alternating layers of conductive carbon black based ink as electrode layers and elastomeric film as a dielectric and electrical insulation. A variety of thin multi-layer sensors were produced to evaluate the manufacturing process. Additionally, using an LCR meter and a tensile test machine, the equivalent electrical capacitance (C) at the two sensor contacts and the applied force are measured, respectively. It is shown that C varies depending on the amount of sample strain caused by the applied force. By testing two versions of DES, a maximum change in capacitance of ΔC = 1.55 pF was achieved. The obtained characteristics show that the presented manufacturing process for the DES can be used as a soft strain sensor to measure the strain caused by the force applied to the elastic element between the jaw couplings.

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Sensor-integrating gears: wear detection by in-situ MEMS acceleration sensors

Peters

Ott

Dörr

et al. 2021

Forsch Ingenieurwes

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Gear tooth wear is a common phenomenon leading to malfunctions in machines. To detect wear and faults, gear condition monitoring by vibration is established. The problem is that the measurement data quality for detection of wear by vibration is not good enough with currently established measurement methods, caused by long signal paths of the commonly used housing mounted sensors. In-situ sensors directly at the gear achieve better data quality, but are not yet proved in wear detection. Further it is unknown what analysis methods are suited for in-situ sensor data. Existing gear condition metrics are mainly focused on localized gear tooth faults, and do not estimate wear related values. This contribution aims to improve wear detection by investigating in-situ sensors and advance gear condition metrics. Using a gear test rig to conduct an end of life test, the wear detection ability of an in-situ sensor system and reference sensors on the bearing block are compared through standard gear condition metrics. Furthermore, a machine-learned regression model is developed that maps multiple features related to gear dynamics to the gear mass loss. The standard gear metrics used on the in-situ sensor data are able to detect wear, but not significantly better compared to the other sensors. The regression model is able to estimate the actual wear with a high accuracy. Providing a wear related output improves the wear detection by better interpretability.

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Requirements for Sensor Integrating Machine Elements : A Review of Wear and Vibration Characteristics of Gears

Cited by 3 publications

References 0 publications

The Effect of Sensor Integration on the Load Carrying Capacity of Gears

The Effect of Sensor Integration on the Load Carrying Capacity of Gears

Manufacturing of soft capacitive strain sensor based on dielectric elastomer material for an elastic element of a jaw coupling

Sensor-integrating gears: wear detection by in-situ MEMS acceleration sensors

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