German coupling manufacturer R+W is bringing a revolutionary data measurement unit to the market in the form of a smart coupling, allowing users to view relevant data from their machines at any time. High-precision measurement data is recorded directly from the drive train and transmitted wirelessly in near real-time to a user-friendly application. This coupling can reduce production times, lower production costs, and improve product quality.

In drive technology, recording accurate torque, speed, vibration, and axial force data can be extremely challenging. The problem is that rotating drive systems make it difficult to record measurement data because direct networking via cables is not possible or the required installation space is lacking. This is where R + W smart coupling technology comes in: integrated sensor technology operates wirelessly. It collects measurement data directly in the drive train and transmits it in real time to smartphones, tablets, computers, or directly to the customer's programmable logic controller (PLC).

Sascha Markert, Head of Development at the German coupling manufacturer R+W, explains: "Smart couplings are an intelligent alternative to torque sensors." "Operators can always view all dynamic parameters and relevant data at a glance via smartphone or tablet to ensure uninterrupted system availability," continues Markert. The standard disc-pack coupling has been upgraded to include integrated sensors, thereby guaranteeing high-precision data measurement technology at a reasonable price.

German R+W Coupling with Integrated Measurement Electronics

Like the standard mechanical coupling series, smart couplings can be easily and flexibly integrated into drive systems. Another advantage is the small space requirement of the coupling, as installation does not require complex auxiliary components. The 2000 integrated battery with mAh capacity allows installation in confined spaces or mobile applications. Alternatively, if constant data measurement is required, an inductive power supply will soon be available for mounting on the smart coupling. This fixed version uses a small box connected to the power system, which is mounted non-contactly a few millimeters below the coupling. Near-field induction provides the required power via a set of integrated coils.

Smart sensors perform data measurement without the need to install external amplifiers. The sensors measure torque, speed, vibration, as well as tensile and compressive forces at a sampling rate of 500 Hz. This data is processed directly in the internal electronics while being transmitted to wirelessly connected systems.

Dedicated Data Transmission for German R+W Couplings

Measurement data can be sent to connected devices in near real-time via a low-energy Bluetooth connection. Operators can choose between high transmission rates or transmissions with particularly low power consumption. Before transmission, the smart coupling performs numerous calculations in the internal measurement electronics. This ensures a high sampling frequency even at low transmission rates, because only the calculated averages as well as minimum and maximum values are sent, saving energy and bandwidth without reducing measurement accuracy. The transmission rate in high-performance streaming mode is 500 Hz, with a battery life of two to three days. In broadcast mode, data is sent at a frequency of 20 Hz, extending the battery life to 7 days of continuous use.

Different connection methods provide options to select the best sensor data representation according to the application. In addition, "events" can be defined: when a defined threshold is reached, these events are recorded in the coupling's memory. For example, this can be a manually selected torque value. If one of these events is configured, the torque values before and after the event are also recorded subsequently after the event occurs. This is possible because the values are continuously written to memory, meaning that values prior to the actual event are also recorded.

User-Friendly Display of the German R+W Coupling Application

All measured variables can be displayed on mobile devices using the proprietary R + W app, where they are processed and clearly presented in various views. Sascha Markert explains the user-friendly interface: "Users do not see the complex measurement technology and the algorithms behind it. Intuitive gesture control makes it easy to use." In the app, the dashboard view displays data in tables as average, minimum, and maximum values. Various scalable graphs track the detailed progression of the measurement data. For example, the multi-graph view allows one measured variable to be displayed over another to easily identify potential correlations.

FFT algorithms are also used for frequency analysis. This allows the torque, forces, and vibrations measured by the coupling to be decomposed from discrete time signals into their frequency components. With this function, amplitudes and frequencies can be clearly displayed and analyzed. Visualization of load spectra in the field of fatigue engineering is already planned. This will involve selecting a segment of measurement data in the application, thereby evaluating and displaying the frequency of torque amplitudes for damage applications. R + W aims to provide customers with established evaluation tools in the application to help them optimize their applications in a targeted manner. The application can also display measurement data from multiple smart couplings simultaneously and present them clearly in charts. Data can be saved as CSV files and then imported into Excel for further analysis.

Condition Monitoring with German R+W Couplings by Connecting to Existing Systems via Universal Interfaces

When developing smart couplings, retrofitting capability and backward compatibility with existing systems were key criteria for R + W. In addition to the application, the smart coupling can be connected to an R + W gateway. This gateway features USB and UART interfaces, as well as four digital and eight analog outputs. A USB cable can be used to establish a direct connection to a computer. Measurement values can be displayed on a PC using third-party software programs such as serial port plotters, MATLAB, or LabVIEW. PLC connections can be implemented via analog and digital interfaces, where the analog and digital interfaces can serve as output monitors for detecting events such as overloads.

This universal connectivity ensures compatibility with common industrial standards for programmable logic controllers. In addition to established systems, new market solutions such as IO-Link, UMATI, or cloud solutions can be implemented. Sascha Markert explains that data security also plays a key role in software development: "Some customers do not want external components in their corporate network." "The R + W app and the R + W gateway for connection to external computers or other cloud solutions allow comparison with existing data outside the corporate network."

German coupling manufacturer R+W is already planning the next step: equipping smart couplings with miniaturized energy converters. This technology, known as energy harvesting, ensures an autonomous energy supply for smart couplings by converting existing and unused mechanical energy into electrical energy. For details on the couplings, please refer to/usercategory/product/529984/。