Smartly integrated and made for the future
The Industrial Internet of Things, or IIoT, is changing not only how companies produce, but also how they monitor, control and optimize their processes. The IIoT uses the networking of machines and devices to generate comprehensive data streams that are analyzed in real time to increase efficiency, quality and sustainability in manufacturing. For R+W Antriebselemente GmbH, the focus is not only on smart components for new plants, but also in particular on retrofits, i.e. the modernization and integration of existing machines into industrial networks.
Wireless measuring unit
The solution specialist's integrated sensor technology, which has proven itself on the market, has digitally opened up the rotating drive train for the IIoT and obtains precise measurement data in the process. In addition to multi-plate couplings, cardan shafts and flanges, R+W's standard product, the bellows coupling, has also been available with integrated sensor technology since the spring.
The main difference to the previous coupling models is the much more compact design of the iBK, which makes it even more space-saving. The iBK offers all the features of the standard coupler while functioning as a wireless measuring unit.
The integrated sensor technology enables the direct transmission of decisive parameters such as torque, speed, acceleration and optionally axial force and lateral force to a gateway. These sensor signals can then be recorded and processed in downstream control systems or data processing systems. Alternatively, it is possible to establish a direct connection to a cloud solution via LTE measuring amplifiers.
In addition, a specially developed app offers the possibility of displaying the data of the measurement chain on mobile devices - i.e. directly at the point of use. This data can be saved and played back for further analysis. Thanks to these different measurement chains, the recorded data is always available on the end device of the user's choice.
Compactly integrated and wirelessly connected
The electronics, including measuring amplifier, are located directly in the coupling itself. R+W has taken care to ensure that the integration of the sensor technology does not affect the mechanical properties of the coupling. Specifically, it means that a standard coupling with a max. torque of 250 Nm, for example, will continue to transmit this after the measuring system has been added. The sensors are then calibrated accordingly to be able to record the optimum range in this torque class.
Torques and axial forces are recorded in a proven manner using strain gauges, an established method. What is new and innovative is the way in which the system is read out: For this purpose, the complete electronics, including the measuring amplifiers, are compactly integrated into the coupling. This enables seamless processing of the values recorded by the strain gauge and immediate transmission to the respective measuring chain.
In addition to a solution with rechargeable battery or induction, energy is also supplied autonomously via energy harvesting. Here, the rotational energy is converted into electrical energy by miniaturized energy converters. Energy harvesting is particularly suitable for applications and installation situations where downtimes are to be avoided, as well as for locations that are difficult to access.
Retrofitting makes machines smart
What makes this solution unique is the possibility of retrofitting the sensor technology in existing plants. Installation is as simple as it is fast, which minimizes the integration effort and acquisition costs. Due to the compatibility with existing components, neither additional installation space nor auxiliary constructions are required.
In the context of the IIoT, the concept of retrofitting is playing an increasingly important role. Retrofitting refers to the updating, modernization and conversion of existing equipment to bring it up to the latest state of the art or to meet specific requirements. Creating connectivity is one of the basic requirements here. Older machines are often not equipped out of the box with the necessary sensors to send data in real time to higher-level systems.
"The integrated sensor technology collects the measurement data directly in the drive train. This transforms a conventional mechanical coupling into a smart component that gives the machine a crucial upgrade for integration into a networked industrial environment and establishes the necessary connectivity," is how Sascha Market, Team Leader Research & Development at R+W, sums it up.
Drives, couplings and cardan shafts are present in almost every machine. This makes the coupling an optimally positioned component for obtaining valuable machine data. The integrated sensor technology from R+W results in an efficient solution for updating existing machines: Instead of carrying out expensive plant replacements, a retrofit using smart couplings offers an economical way to integrate existing resources into the IIoT and make them fit for the future.
R+W's sensor technology can be seen at the SPS trade show in Hall 3A, Booth 121.
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