attempts for real time sensing in tribo contacts - ways to ... · motivation 2 10/12/2016 prof. dr....

Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital

Tribology

MENSUS Session Prof. Dr. W. Holweger

[email protected]

2016-10-11

mailto:[email protected]

Agenda

10/12/2016 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST 1

Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology

1

2

3

4

5

Motivation

„In Situ“ Chemical Sensors for Life assessment -Principles

In Situ“ Chemical Sensors for Life assessment -Results

Summary

Mechanical Sensors –Sensotect®

Summary

Motivation

10/12/2016 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST 2


Components add to the System – Life Cycle of the System creates the

entire Value

Components

System

Product

Motivation

10/12/2016 3


Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST

Components add to the System – Life Cycle of the System creates the

entire Value

System

Components Product Life

Life

Life Cycle

=

Value

Value

Added

Value

Motivation

10/12/2016 4



System


Life

Life Cycle

=

Value

Value

Added

Value

Data aquisition

Engineers Office

Data processing Cloud

=

Digital Twin Dataprocessing

Cognition Map Reactive Maintenance

SCADA Supervisory Control and Data Aquisition

Motivation

10/12/2016 5



SYSTEM

System


Life

Life Cycle

=

Value

Value

Added

Value

Properties

P1

.

.

pn

Properties

P1

.

.

pn

Properties

P1

.

.

pn

Interpreter

Digital twin

of the system

Aim

To change the

component into

a Systems sensor

Example : MEMS

Motivation

10/12/2016 6




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Advantage Sensotect®:

Directly coated Sensor Layer.

No adhesives.

No transfer polymers.

High strain sensitivity.

No aging drift.

No temperature creeping.

Ω

The Component acts as Sensor

Schaeffler Coating Tool Box

Corrotect®

Corrosion Protection Wear Protection

Durotect®

Insulation

Insutect® Triondur®

Sensotect®

Sensor Coating Friction Reduction


10/12/2016 8



Ω

• For strain measurement, a strain sensitive alloy is deposited by advanced PVD (Physical-Vapour-Deposition) technique.

• These structures allow the calculation of the local stress condition, even if they are applied outside of the tribological contact.


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Steering shaft

Automotive

Wheel

bearing

Automotive

Bicycle

Bottom bracket

Consumer Products

Thrust Bearing

Industrial

• Application of strain gauges is independent from substrate geometry.

• 3D- as well 2D-applications are state-of-the-art.


Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital TribologySensotect®

2D-Samples

3D-Bearing

Ω

10/12/2016 10 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST

• Application of strain gauges is independent from substrate geometry.

• 3D- as well 2D-applications are state-of-the-art.

http://wiki.schaeffler.com/project/project-01/images/2/2e/Pic01_f-574629_02.jpg

http://wiki.schaeffler.com/project/project-01/images/f/f0/F-563099_01-0011_au-m46_010_pic01.jpg


10/12/2016 11



• High Sensitivity.

• Excellent Linearity und low Hysteresis Deviation.

Torque Measuring Steering Shaft

15,2 15,5

Hysteresis < 0,1 Nm

0,25 % FS



Benefits of Sensotect® Sensor Element:

Modular, standardized design.

High output and low geometry-related risk.

Low unit costs due to low component size.

Sensor Sleeves for Long Shafts

Sensotect® Sensor-Element

> 400 mm

• Cost Reduction by coating small Sensotect Sensor Elements.




0

500

1000

1500

2000

2500

-100 50 200 350 500 650 800 950 1100

Se

ns

or

Sig

na

l [-

]

Torque Reference [Nm]

Sensor Sleeves for Long Shafts


502 503 504

Hysteresis < 0,5 Nm

0,05 % FS

Sensotect® Sensor-Element with

wireless Data Transmission.



To

rqu

e in

Nm

Time in sec.

Online Torque-Measurement




Sensotect enables e.g.

continuous torque-

measurement in e.g.

steering shafts or E-Bikes

during operation.

Complete demonstrator

systems are realized.

Functional Validation

performs excellent

sensitivity, low linearity-

and hysteresis deviation

Function is proven for several

Schaeffler applications.

Sensotect :

Sensor Coating System:

Directly coated strain

gauge system without

polymer adhesives or

transfertape.

Next Steps:

Ready to be developed for series production; search for pilot customer / application



10/12/2016 16



Component Segment

Tribosystem

Take the lubricant as a sensor

Digital Twin Tribosystem

Lubrication

Digital Twin System

Digital Twin Mechanics

(Megatronic)

System and it‘s components

.. And their twins …

Combine to a


10/12/2016 17



Component Segment

Tribosystem

Products pi

Plus

Environmental

noise De

𝐿𝑢𝑏𝑟𝑖𝑐𝑎𝑛𝑡 = 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑉𝑒𝑐𝑡𝑜𝑟

C1

.

.

Cn

C11 ……….C1n

.

.

Cn1………….Cnn

Components

(Baseoil, Additives

Components

Self Interaction

C11s ……….C1ns

.

.

Cn1s………….Cnns

Interaction with Surfaces


p1

.

.

pn

Products

ev1

.

.

ev n

P1 +De

.

.

Pn+De

Environment

Interaction = Self Interaction Interaction with Surfaces

Products Environment


10/12/2016 18



Rolling

element

Life is determined by the distribution of the lubricant within the contact as there are

Cage - Rolling Elements

Rolling Elements toward OR/IR

Life ~ D (t+1)~ 𝐷 𝑡 𝐿𝑖𝑓𝑒 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑡ℎ𝑒 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑛𝑡 over time (t) : D(t) : How much lubricant gets lost – how much does enter again

Example : TRB Test stand

A : Original lubricated

B : After test

A

B


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Component Segment

Tribosystem


Running in Phase

Components merge

Lubricants get distributed

Steady State

Incidential effects

causes lack of lubrication

Metal to metal

Contact – Debris

formation

Sensor How does a

lubricant act in

the presence of

metal and debris

(as a consequence

of starvation)

System in time


10/12/2016 20



FE 9 Test Bench for Grease Life

Test bearings DGBB

Support Bearings

Heating elements

Take volatile products

from ageing and detect

by Gas-Chromatography

plus Mass Spectrometry

5.0 10.0 15.0 20.0 25.0 30.0

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

(x100,000)

5.0 10.0 15.0 20.0 25.0 30.0 35.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

(x100,000)

Black : Original

Purple : 50 hours -

Black : Original

Purple : 100 hours -

Some Products

Test Bench

FE9 Grease Life Test

Test benches

Absorption unites


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Adsorption of volatile reaction products

Test benches

Absorption unites

Test unit

Co

nce

ntr

atio

n o

f C

arb

onyl

Co

mp

ound

s

Aldehydes

Aldehydes + Ketones

Ketones

Carboxylic Acids

Failure detected by

friction

„In-situ“ Detection of Catalytic Degradation enables early failure

detected by an increase in friction

Time (hrs)


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Creation of Digital Twins

in Tribosystems

• Mechanical by Strain Gauge units at place

• Chemcial by „in situ“ Spectrometry

Leads to Predictive Reactive Maintenance

Adds to SCADA

Cloud

Cognition Map

Prediction of

Complex Systems

In real time

THANKS for YOUR ATTENTION

attempts for real time sensing in tribo contacts - ways to ... · motivation 2 10/12/2016 prof. dr....

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