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

根据SPP 2305的目标，该项目旨在开发在径向轴封(RSS)中集成传感器的基础，同时保留其主要功能和外部尺寸。集成的附加功能还包括用于数据采集和还原的外围设备以及无线能量和数据交换。在这里，应使用既定的标准。应监测的对密封和系统功能具有特殊重要性的测量值包括密封接触和润滑剂的温度、密封的摩擦力矩、外壳压力和润滑剂红外光谱的选定波段，以评估其老化情况。为了能够适应测量参数和数据处理算法，微电子学的软件将是可更新的。由于在项目过程中将出现复杂的、跨学科的挑战，密封技术初级教授(机械元件、齿轮和传动研究所)、测量和传感器技术教授和理工大学凯撒斯劳滕微电子系统设计教授之间的合作被启动，以成功完成该项目。基于传感器和RSS的耦合模拟，传感器的最佳位置以及密封和传感器的交叉影响将被研究。同时，在实验室调查中，传感器概念将得到验证。随后，将设计微电子和传感器技术，并制造电路板。在一步一步的方法中，将验证传感器集成密封件的功能。从独立的实验室测试开始，测试将逐步发展到在现有的密封试验台上进行全面测试。除了密封件的功能外，还将研究密封件本身及其环境对能量和数据传输以及能量消耗的影响。所有项目成果都将记录在传感器集成密封件的设计框架中。与其他机械元件相比，它们位于机器和环境的交界处，因此可以以较低的工作量更换RSS。这意味着，具有传感器功能的RSS可以通过更换密封或简单地最初安装传感器集成密封而不是标准密封来轻松集成到现有设备和设计中。它们与润滑剂直接接触的位置非常适合监控润滑剂质量，这与目前最先进的径向轴封相比具有明显的优势。

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.