Condition monitoring of marine gearboxes based on wireless, energy-autonomous sensor nodes

Industry 4.0
XXL products
Project title Condition monitoring of marine gearboxes based on wireless, energy-autonomous sensor nodes (CoMoGear)
Project duration 01.08.2016 – 31.07.2018
Press release

Cost-effective condition monitoring of highly stressed components in marine transmissions is the aim of the research project CoMoGear. For this an energy self-sufficient and wireless sensor network is developed. Miniaturized sensor nodes monitor torque, rotational speeds, temperatures as well as the wear condition of the torque transmitting components. The energy needed to operate the sensors is obtained from the environment, for example by using the generator principle at the input or output shaft. Thus, the system operates wirelessly and without an external energy supply, whereby the installation and maintenance costs decrease significantly. Sensor and radio technology and autonomous energy supply are to be brought together to a condition monitoring system (CMS) in the course of the research project. In addition, a demonstrator shall be developed.

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  • 17.01.2018, 10:00 h - 15:00 h
  • IPH (Seminarraum), Hollerithallee 6, 30419 Hannover
  • 06.09.2017, 10:00 h - 14:00 h
  • Mircosensys GmbH, Erfurt
  • 11.05.2017, 10:00 h - 14:00 h
  • Reintjes GmbH, Hameln
  • 18.01.2017, 11:00 h - 14:00 h
  • IPH – Institut für Integrierte Produktion Hannover gGmbH, Hollerithallee 6, 30419 Hannover
  • 24.08.2016, 13:00 h - 15:30 h
  • HSG-IMIT, Institut für Mikro- und Informationstechnik, Wilhelm-Schickard-Str. 10, 78052 Villingen-Schwenningen

Publications about the project

This paper describes the development and prototypical implementation of an energy self-sufficient sensor for condition monitoring of wet-running steel disc clutches in marine gearboxes. For the precise control of an automated system and the monitoring of its performance, the knowledge about the possible wear is an essential prerequisite. In addition, the storage of sensor data over the life of the system offers the possibility of long-term condition monitoring. The combination with various other technological components creates a solution that enables cost-effective condition monitoring of marine gearboxes. Compared to existing systems, for example, the costs for installation and maintenance are significantly reduced. Both the methodology from the morphological box to the fine concept as well as the first measurements of the sensors are presented.

automated system, condition monitoring, metrology, clutch, gearbox

Rotary energy harvesters offer the possibility of generating energy in the center of rotation or outside of the center of rotation. There are both concepts with reference to the outer housing as well as different concepts without a fixed reference. In addition, Energy Harvester solutions are available that provide energy to the housing and generate energy through the rotation of the shaft. The selection of a concept must be made individually for each application and depends on various influencing factors. Decisive in particular are the installation space, the energy requirement of the sensor node and the speed.

energy supply for microsystems, energy harvesting, rotary energy harvester, power management

Marine gearboxes ensure the reliability of the entire ship. Therefore a timely maintenance is crucial. To decrease maintenance costs and increase security, IPH develops a wireless and energy-autonomous measurement system to monitor marine gearboxes from afar.

gearbox, ship, condition monitoring, maintenance


The project no. 03SX417A was funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) in the research programme Next-Generation Maritime Technologies and coordinated by Project Management Jülich (PTJ).


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