Smart acoustic sensors minimize machine downtime
In industrial conveying technology, axial piston pumps are often used to lift heavy loads. An unforeseen failure of these widely used systems is usually associated with high costs. Researchers at Fraunhofer IDMT have therefore chosen the axial piston pump as a practical example for the acoustic monitoring of machines. If it no longer runs completely trouble-free, the experts can recognize this from their noises.
Locally installed, battery-powered sensor systems pick up pump noise via the air or as structure-borne noise, compare it with reference audio data and forward the collected information as metadata. This retrofittable solution allows not only a basic statement about the condition of the machine, but also the identification of various types of problems, such as bearing play or problems with the hydraulics, before major damage occurs. The maintenance technician can use the information to start maintenance work in a targeted manner, which saves a great deal of time and money.
At the upcoming Hanover Fair, the institute will present its development using a demonstrator. This allows the wireless sensor nodes to be configured on a tablet. Recognized acoustic events are visualized on a dashboard. In practice, the system can be easily retrofitted and integrated into existing communication and sensor infrastructures.
With acoustic condition monitoring, reliable machine performance can be offered as a service and sold with alternative business models, e.g. via leasing. The generated data will be available for further use in the industry 4.0 context.
“This opens up an extension of their product portfolio for plant suppliers and alternative procurement options for their customers,” explains Danilo Hollosi, Head of the Acoustic Event Detection Research Group at Fraunhofer IDMT. The institute is currently working on the development of further business cases, says Hollosi.
An important added value of the monitoring system stems from the fact that a large part of the data processing takes place locally at the sensor. Thus, it can also be used in critical facilities and infrastructures or remote locations. Based on their extensive experience with security-critical requirements, the Fraunhofer scientists can configure the system so that it can be used locally and without an Internet connection, depending on customer requirements.
In the “ACME 4.0” project, which is funded by the German Federal Ministry of Education and Research, Technology Readiness Level 7 has been achieved. In 2018, the focus was on field trials with application partners in the fields of energy management, water management, heavy industry, special mechanical engineering, plant construction and materials handling technology. In addition to pumps, motors, turbines and compressors were also tested. Industrial partners of the project are Bosch Rexroth and Infineon.
Further information: https://www.idmt.fraunhofer.de/en/hsa.html
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