The integration of sensors in machine elements is becoming increasingly important, as sensor-integrated machine elements not only offer improved monitoring and control of processes, but also enable faster and more precise commissioning of systems. Sensor-integrated machine elements offer the option of retrofitting existing systems with sensor functions or making minor changes.
The challenges of commissioning roll forming processes
The commissioning of roll forming processes is often time-consuming and has often been based on experience. This often leads to rejects until the correct machine setting is found. This is where the integration of measurement technology into the machine elements comes in. By measuring the load on the individual rollers, processes can be made more reproducible and efficient. core sensing has worked with its partners to solve this problem. Sensor-integrated machine elements have been developed.
The load path and node model: A possible approach to the development of sensor-integrated machine elements
The load path and node model was chosen as the methodological approach to analyze the roll forming line, select suitable machine elements and develop these further into sensor-integrated machine elements. The load path and node model offers a decisive approach for the development of sensor-integrated machine elements. It enables the evaluation of different equivalent variables and supports the developer in the decision-making process by taking into account the complexity and uncertainty in the creation of calculation models between the equivalent variable and the desired measured variable.
Load path and node model optimizes roll forming systems with cardan shafts Efficient analysis and minimization of changes
By applying the load path and node model, it was first shown that cardan shafts between the gearbox and the frame proved to be a good solution, providing sufficient accuracy and requiring minimal or no changes to the roll forming line design. It was then demonstrated how the load path and node model can be used to analyze the cardan shaft to identify a unique load path and recurring elements within the cardan shaft. This allows for minimization of changes to the existing design and manufacturing steps.
Realized customer project - sensory cardan shaft
In collaboration with the cardan shaft expert Elso Elbe and the digitization expert core sensing is based on coreIN an innovative sensory cardan shaft that can make an important contribution to the digitalization of machines and systems and thus Assistance systems, Condition monitoring- and Predictive Maintenance-solutions. The sensory drive shaft not only enables the measurement of torque and speed, but can also be retrofitted as a replacement component or installed as a special OEM version. The use of the sensor drive shaft can shorten commissioning times and reduce dependence on the operator's experience.
The future of mechanical engineering
The integration of sensor technology in machine elements offers a number of advantages for mechanical engineering. It enables more precise monitoring and control of processes, shortens commissioning times and reduces the dependency on operators' experience. This is why the project engineers at core sensing work actively and in close cooperation with their partners, the manufacturers of machine elements as well as machines and systems, on the development of sensor-integrated machine elements and contribute their scientific expertise.
Overall, sensor-integrated machine elements play a key role in the further development of mechanical engineering. Their use makes it possible to improve the performance and efficiency of machines and systems as well as employees by creating an assistance system and contributes significantly to the competitiveness and future viability of the industry.