Smart Couplings Remove Guesswork from Measurements in Machinery Applications

Quite often, the collection of precise data in drive technology applications can be problematic. Data monitoring in a rotating drivetrain is difficult because a direct networking cable connection is often not an available option. Nothing sends shivers down the spine of for example, a production line manager or a system integrator like uncertainty. That’s why achieving precise measurement of things like torque and other parameters in machinery applications is, while daunting, a dearly desired goal, especially if those measurements are only available at the drive and motor. Accordingly, couplings used in machinery and other applications today are being developed with a “smarts” and “intelligence” never seen before in such hardware. Coupling manufacturers are now producing couplings with leading edge measuring capabilities by virtue of adding sensors and software to the equation. These custom coupling are thus creating a new paradigm in manufacturing by enabling the wireless transmission of mechanical data from directly within components like, for example, a rotating drivetrain. Call it “smart” or “intelligent” coupling (take your pick), this new technology provides a coupling system with measurement capabilities that are taken directly in the drivetrain, providing enhanced data acquisition and enhanced transparency in the drivetrain in a timely manner. Following in much greater detail is a discussion regarding this latest advance in coupling technology. Our responders include: Andy Lechner (AL), VP-Sales & Marketing of R+W; Todd Lehman (TL), sales manager, Coupling and Drive Technologies, Voith Turbo North America and Christopher Hoeweler (CH), condition monitoring expert, Voith Digital Ventures; Tim Nageli (TN), global sales manager-mill products-Ameridrives and Mark O’Neil (MO), chief principal engineer, Altra Couplings; and Ralf Epple (RE), product manager at Mayr Power Transmission in Mauerstetten.

In drive technology, why is accurate measurement of torque and other parameters in machinery (drivetrain) applications so important? Andy Lechner (AL)/R+W: All components in a mechanical drive line have limits to the amount of torque they can withstand before failure, and as machine designs are continually optimized for size and weight, while running faster, the margin of safety from torque overload is becoming smaller. Conditions detrimental to machine performance such as wear, misalignment, loss of lubrication and binding of workpieces all increase the amount of torque required to make the machine move. So an accurate measurement of the torque being applied at key locations in the drive line can be essential to condition monitoring and predictive maintenance. Similarly, vibration can be caused and exacerbated by these same detrimental conditions, as can the axial force applied to shafting as a result of movement and heat generation. Having the ability to measure changes in these parameters is also useful in monitoring the overall health of rotating equipment. In other instances, particularly in the process industry, changes in the density and viscosity of materials being mixed, pressed, pumped or extruded can manifest themselves as changes in the torque required to drive the process. Here too, accurate measurement of torque can aid engineers in optimizing quality and throughput. Todd Lehman/Christopher Hoeweler (TL/ CH) Voith: Remote monitoring of equipment provides operators and equipment manufacturers the ability to see what’s happening with the drive chain. This visibility allows operators to make strategic decisions about the operation of the machine and the process

that it is performing. The accuracy and timeliness of the measurement will provide the operator the ability to maximize machine productivity without exceeding individual drive chain component capacities. In addition, equipment monitoring can provide the ability to produce trend data for each monitored component of the drive chain. This can help operators make decisions about the health of each drive component allowing them to order spare parts in preparation for repair. A good example is our OnCare.Health ACIDA—Report generator. The measurement is not only dependent on the accuracy but also on the reliability of gathering the data. It is important to trust the data to make decisions on actions improving maintenance or operations. It is also noted that the torque signal is also carrier of health information of the driveline. Tracking natural frequencies, for instance, allows the ability to pinpoint changes in the system characteristics which may have been caused by rotor cracks.