Integration of Sensors for Enhanced Condition Monitoring in Polymer Gears: A Comparative Study of Acceleration and Temperature Sensors

As an integral part of a machine, gears are subject to wear, which is influenced by a number of factors. For polymer gears in particular, the uncertainties due to wear are high. These uncertainties outweigh the advantages of polymer gears, such as lower inertia. Improved condition monitoring, for example, with better data acquisition, could reduce these uncertainties and is therefore of great interest. This study addresses the challenges of condition monitoring in polymer gears by investigating the integration of sensors directly onto the gears for improved sensitivity. A compact sensor module mounted on a polymer gear is presented to demonstrate the benefits of integrated sensors. The research compares the effectiveness of integrated acceleration and temperature sensors with state of the art external methods. The results show that the in situ sensor module (ISM) provides reliable measurements for condition monitoring with integrated sensors. A comparative analysis with methods based on the current state of research highlights the increased sensitivity of condition monitoring based on the ISM acceleration sensors compared to traditional bearing block sensors. This increased sensitivity shows a clear advantage of integrated sensors over established methods. The temperature curve of the integrated sensors is sensitive to abrasive wear and gear failure, indicating the wider potential of integrated temperature sensors. In conclusion, this research lays the foundation for advanced condition monitoring using integrated sensors in polymer gears. The knowledge gained contributes to optimising gear applications, promoting cost-effectiveness and aligning with the principles of the Internet of Things and Industry 4.0.