Condition monitoring of a grinding machine – Realization of a "sensing grinding spindle" by integrated sensors

Use Case Titelbild: Condition Monitoring einer Schleifmaschine

Objective

Wireless integration of radio sensors in a grinding spindle of a machine tool to measure vibrations and forces occurring during the grinding process.

Client

Institute of Production Engineering and Machine Tools, Leibniz University Hannover

Project period

2021 / 2022

Challenges

  • Extremely small installation space (30 x 5 x 5-8,5) mm
  • Battery charging without retooling the machine
  • Resistance of electronics to high temperatures (85°C)
  • Wireless data transmission from the inside of the machine / through the seal
  • Electromagnetic interference from the additional eroding process and the spindle drive

Realization

  • Integration of a wireless measuring system in four tiny recesses of a grinding spindle
  • Development of a board for data acquisition (DAQ) and data transmission with integrated MEMS 6-DoF-IMU for the measurement of accelerations, rotation rates and temperature (16 bits, up to 6,5 kHz sampling rate) as well as for the connection of 4 semiconductor strain gauge full bridges (24 bits, up to 1,5 kHz sampling rate)
  • Development of a power management board for connection of the rechargeable battery
  • At downtime of the machine: autonomous connection of a voltage source via a stylus for charging the Li-Ion battery with high charging power (2 minutes battery charging for 8 minutes runtime, max. 80 minutes)
  • Wireless data transmission via board-integrated antenna per 2.4 GHz radio link to a nemi Connect receiver module

Advantages

  • Structure-integrated measurement of condition data of an autonomous machine tool
  • Mapping of sensitive properties by integrated sensors in the machine tool
  • Reliable wireless data transmission even through seal and housing of the machine tool
  • Energy supply concept suitable for series production
  • Autonomous, fast battery charging during short machine downtimes
  • High measurement data quality / low noise due to energy supply via rechargeable battery

Deployed nemione® products

  • nemi Connect
Charging Contact
Telemetry Board
Power Management Board
Li-Ion-Akku
Graphic: mode of operation grinding spindle
Logo IFW - Institut für Fertigungstechnik und Werkzeugmaschinen

„Within a very short time, i4M technologies designed, developed and manufactured a fully functional, wireless telemetry system for the condition monitoring of a tool grinding machine. The telemetry system is very small, battery-powered and fully integrated into the grinding spindle. The system reliably

transmits from a machine tool. This solution enables structural integration of sensor technology on rotating machine components, so that process forces can be detected close to the point of action and additional cost-intensive measurement technology components can be dispensed with. I also articularly

liked the uncomplicated and goal-oriented cooperation with the team.“

M.Sc. Henning Buhl

Head of Department Machine Components

Institute of Production Engineering and Machine Tools,

Leibniz University Hannover

Download Use Case

Use Case Overview

Contact

We are looking forward to getting into conversation with you and to starting a partnership to find the optimal solution for your challenges.

Martin Noll

i4M technologies GmbH

Foersterstr. 5
52072 Aachen
Germany

+49 241 56 00 22 00

sales@i4m-tech.de

LinkedIn