Sensor-integrated machine element radial shaft seal for monitoring of operation conditions and lubricant quality

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According to the objectives of the SPP 2305, this project aims to develop the fundamentals for the integration of sensors in radial shaft seals (RSS), while preserving their primary function and outer dimensions. The integration of additional functions also includes the peripherals for data acquisition and reduction as well as the wireless energy- and data exchange. Here, established standards shall be used. Measurement values with special importance for seal- and system function that shall be monitored are the temperature of the sealing contact and the lubricant, the friction torque of the seal, the housing pressure and selected bands of the IR-spectrum of the lubricant in order to assess its aging. To be able to adapt the measurement parameters and data processing algorithms, the software of the microelectronics will be updateable.Due to the complex, interdisciplinary challenges that will arise during the project, a cooperation between the junior professorship for sealing technology (institution of the institute of machine elements, gears and transmissions), the professorship for measurement and sensor technology and the professorship for microelectronic system design at the TU Kaiserslautern was initiated for the successful completion of the project.Based on coupled simulations of sensor and RSS, the optimal position of the sensors and the cross-influences of seal and sensors will be investigated. Simultaneously, in lab-investigations the sensor concepts will be verified. Subsequently, the microelectronics and sensor technology will be designed, and circuit boards will be manufactured. In a stepwise approach, the function of the sensor integrated seals will be verified. Starting with stand-alone lab tests, testing will evolve gradually to a full-scale test on established sealing test benches. Besides the function of the seal, the influences of the seal itself and its environment on energy- and data transfer as well as energy expenditure will be investigated. All project results will be documented in a framework for the design of sensor integrating seals.Compared to other machine elements, their position at the junction of machine and environment allows for a replacement of RSS with rather low effort. This means, that RSS with sensor functions could be easily integrated in existing devices and designs by changing the seal or simply initially installing the sensor integrated seal instead of the standard seal. Their position with direct lubricant contact is ideal for the monitoring of lubricant quality, which provides a distinct advantage compared to the current state of the art radial shaft seals.