What sensors in threaded spindles can do
Smart threads should make force and torque measurement technology in systems and machines with threaded spindles superfluous – Bornemann shows how this works.
The idea is as obvious as it is clever: why shouldn’t threaded spindles simply become sensors themselves? With such a solution, plant and machine manufacturers could in future dispense with the cumbersome and costly integration of external force and torque measurement technology. At least that is the idea of the development team at Bornemann Gewindetechnik GmbH. The family-run company near Hildesheim now develops, designs and manufactures customer-specific thread components with intelligent sensor technology. This means that manufacturers and operators of systems or machines with threaded spindles will no longer have to rely on pressure cells from Research & Development.
The sensor technology is integrated directly into the threaded spindle and records every interaction of the component with its environment. This allows different measurement data to be collected, linked and stored within the component using miniaturized sensor electronics. The data is transmitted wirelessly to an app or the company’s own networks. The smart threads therefore allow valuable conclusions to be drawn about the load on components. The sensors installed inside the thread measure tension or pressure, torsion, rotation, position (X, Y, Z) or temperature.
Use different sensor types in the threaded spindle
Manufacturers often prescribe specific lubricants for the proper operation of their systems or machines.
- Torsion sensors can measure the breakaway torque of a loaded threaded nut, for example. The torsion data collected can also be used to determine which lubricant has been used. This allows an operator to replace an incorrectly used lubricant with the manufacturer’s compliant lubricant and thus optimize their processes. Torsion sensors can also be used to draw conclusions about operating errors on systems.
- Other sensors measure the tension or pressure and therefore the loads. In this way, the smart components from Bornemann Gewindetechnik can be used for weighing, especially for detecting overloads. For manufacturers of heavy-duty lifting systems, threads with integrated tension and pressure sensors are recommended as an intelligent alternative to cost-intensive load cells. In addition, smart threads with tension and pressure sensors may offer the option of identifying the respective model via the specific load profile in lifting systems with several lifting jacks (e.g. in lifting systems for locomotives and wagons).
- Position sensors integrated into threaded spindles also allow conclusions to be drawn about the condition or wear of a system, e.g. by measuring the smallest vibrations.
- Information on overload or wear can also be provided by temperature sensors.
Wireless data transmission possible
The measurement data is recorded, merged, stored and transmitted wirelessly directly in the component. This is done via Bluetooth to a customer-specific app provided by the manufacturer so that users can view all measured values on their smartphone or tablet. The signals can also be received and pre-processed using an industrial gateway and then forwarded to higher-level measuring systems or controllers via industrial bus systems. This ensures that the smart threads are compatible with existing systems.
Bornemann Gewindetechnik develops these “feeling” components for manufacturers or operators in the plant and mechanical engineering sector where threaded spindles or screw conveyors are used. One target market includes manufacturers and operators of lifting systems that have to cope with heavy loads, e.g. lifting systems for trains, trucks, theater stages and ships. Another area of application is large gate valves or bulkheads for hydraulic steel structures.
Measurement data collected over the long term can be evaluated and used to draw conclusions for process optimization. Among other things, the information helps to initiate predictive maintenance and avoid unnecessary system downtimes.
Moritz von Soden, Managing Director Bornemann Gewindetechnik GmbH & Co. KG.
Users of smart threaded spindles benefit from important additional information about their components and processes. Measurement data collected over the long term can be evaluated and used to draw conclusions for process optimization. Among other things, the information helps to initiate predictive maintenance and avoid unnecessary system downtimes. Sources of error and operating errors can be identified more easily. In addition, the data and derived statements can be used to improve the design of components and increase the energy efficiency of machines or systems.
From the prototype to the small series to the final product
If, for example, a machine manufacturer orders a smart thread, the first step is to produce a prototype consisting of the manufacturer’s slightly modified mechanical product and a standardized sensor system plus software.
The machine manufacturer is already using small thread series and an app tailored to his company. This enables him to obtain important feedback from his customers on the machines and systems equipped with the thread. This feedback is used to further develop the software in a targeted manner and implement application-specific functions. Intelligent algorithms can also be implemented to offer the end user significant benefits compared to the conventional product.
Weaknesses of previous solutions for force and torque measurement technology
According to the Bornemann Gewindetechnik team, the solutions for force and torque measurement technology available on the market to date have clear weaknesses: cumbersome integration, high acquisition costs, complex measuring chains – Industry 4.0 and its requirements can hardly be implemented in this way. Smart thread components are designed with the future in mind and are intended to solve these problems. The new threads from Bornemann Gewindetechnik digitize different machines and systems, making them smart. They act as an integrated interface for the Internet of Things and professionalize the overall system of plants and processes.
Source:
Dipl.-Ing. (FH) Sandra Häuslein (13.10.2021), Was Sensoren in Gewindespindeln bewirken können, https://www.konstruktionspraxis.vogel.de/was-sensoren-in-gewindespindeln-bewirken-koennen-a-1062221/