Future sensor set efficient intelligence in one can achieve state monitoring
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The sensor system will be applied to machine monitoring and can quickly detect the abnormal operation of the machine. With the help of this sensor system, the factory can prevent the unplanned shutdown of production machinery.
Through the application of the sensor system, the company can also perform precise maintenance on the equipment when it needs maintenance, rather than strictly performing regular maintenance, which is expected to reduce maintenance and repair costs by 30%.
The AMELI4.0 research project aims to increase the German company's market position in the "Industry 4.0" era. For this purpose, the German Federal Ministry of Education and Research (BMBF) will use it as part of the "IKT2020 Innovation Research" project to fund the AMELI4.0 project of 3.84 million euros (about 4.28 million US dollars).
Strict requirements for sensors Sensors will play a key role in the "eyes and ears" of machines and workpieces in Industry 4.0. They can collect information on the status and performance of machines and workpieces. In order to achieve intelligent management and interconnected manufacturing, sensors must be able to collect and process large amounts of data in real time.
At the same time, these sensors also need to be as energy-efficient as possible and easily integrated into complex production systems. Industrial sensors that are widely used today cannot meet the requirements of "Industry 4.0". For many applications, they are not smart enough or flexible enough. They not only consume too much energy but also are expensive.
MEMS Sensors for Industrial Applications To achieve the research goals of AMELI 4.0, researchers are turning to one of the key technologies in the connected world: MEMS sensors.
Even now, it is impossible to imagine what would happen to automotive and consumer electronics without MEMS sensors. For example, MEMS sensors are the core components of the ESP electronic body stabilization system. They also ensure that the screen of the mobile phone will follow when we rotate the smartphone.
MEMS sensors are smaller, smarter, more energy-efficient and more economical than traditional industrial sensors. However, they are not stable or strong enough to meet the requirements of the industrial environment in many aspects.
This means that some potential production system condition monitoring applications have not yet been developed. The AMELI 4.0 research team plans to further develop MEMS sensors to meet the requirements of industrial applications.
Energy supply plays an important role here: The new sensor system will not require a power cord or battery, and its design is to generate electrical energy through the vibration of the machine (energy harvesting), fully achieving energy self-sufficiency.
Use noise differences to achieve condition monitoring In order to monitor the machine, the new sensor system will measure two types of noise: one is structural noise, which is vibration noise inside the machine, and the other is acoustic noise, which is the noise emitted by the machine. When a machine is working abnormally, its vibration and noise are different.
The sensor system will compare the measured noise signal with the previously stored data. The sensor system can also continue learning. When the signal changes to indicate defects, damage or wear, the system will respond accordingly. Therefore, the future sensor system can Monitor when the machine needs maintenance or repairs.
In more complex systems, this intelligence assessment can be handled by a gateway (or router) that transmits data to a router or to a computer network system in a manufacturing plant.
The Network Research AMELI 4.0 project brings together leaders from all sectors of the global industry and academia to jointly advance the innovation and development of new sensor technologies. These partners include sensor technology, systems and mechanical engineering, monitoring of machine conditions, and energy conversion. Microtechnology and so on.
Robert Bosch as the leader in the MEMS sensor market led the project research and advancement. Other partners include Siemens, Hahn Schickard Gesellschaft, Fraunhofer Institute for Production Systems and Design Technology, Binder-Elektronik GmbH, Schaudt Mikrosa GmbH, and Stackforce GmbH.
The AMELI 4.0 project launched in December 2015 ("Industry 4.0" condition monitoring application MEMS system) is expected to be completed by the end of 2018.
(Original title: Industrial sensor head Zheng Sheng, Bosch led the AMELI 4.0 project to occupy the scientific and technological heights)