Condition monitoring

Products and services

Optical, acoustic and electromagnetic sensors, sensor systems and monitoring systems for the condition and lifetime evaluation

 

Fraunhofer IKTS provides optical, acoustic and electromagnetic sensors, sensor systems and monitoring systems for the condition and lifetime evaluation. They are used for materials, structures and components, but also in processes as well as entire plants. With the systems of Fraunhofer IKTS on-site measurement services for real-time monitoring and associated condition-based maintenance and optimization of plants are possible.

© Fraunhofer IKTS
Sensor ring – monitoring of welding joints and corrosion.
© Fraunhofer IKTS
Dynamic fatigue test on a rotor blade test facility.
© Fraunhofer IKTS
Rotor blade diagnostics in a wind farm near Hof (Germany).

Materials, structures and components

 

Sensor ring – monitoring of welding joints and corrosion

The sensor ring is a new measurement system for the monitoring of welding joints regarding cylindric objects. With the help of special ultrasonic waves, edge and fusion defects are detected. This enables conclusions concerning the quality of pipe constructions, such as jackets or tripods in the offshore sector or pipelines. The acceleration of cyclic safety tests, the increase of defect resolution as well as optimization of measures planning are only some of the advantages provided by the solution of Fraunhofer IKTS, which reduces maintenance cost.

For more information on the sensor ring, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Fatigue tests regarding fiber composite components

For the early detection of damages in components of fiber composites, tests are accompanied by various measurement technologies. Although environmental noise and disadvantageous, materials-limited acoustic properties occur in the case of composite materials, Fraunhofer IKTS can record damage behaviors in a full-scale test. The results enable specific constructive adaptations of the test procedures or the components.

For more information on fatigue tests, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Monitoring system for rotor blades

The integrated system for the monitoring of rotor blades of wind power plants detects and classifies damages. This enables the operators of wind power plants to optimize the reliability of the components. By means of a condition-based maintenance, services can be planned more flexibly.

For more information on the monitoring system for rotor blades, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Ultrasonic scan carriage – detection of undulations, bar adhesions and delaminations

The ultrasonic scan carriage was specifically designed for the analysis of the main load zone of a rotor blade. By means of extensive scans in the pulse-echo-mode, defects, like cracks, dry spots, air inclusions, undulations, delaminations as well as bar adhesions can be detected and monitored. The ultrasonic scan carriage combines innovative measurement technologies (PCUS® pro) with a modern control and evaluation software (PCUS® pro Lab). A rotary encoder enables coordinate-based measurements and, hence, an exact defect localization.

For more information on the ultrasonic scan carriage, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Structure-integrated sensors for damage detection

An optimal and reliable monitoring of fiber composite components often requires the integration of electronics and sensors into the respective modules. This assures an effective coupling and decoupling of the ultrasound. By means of a condition-based maintenance, resources are preserved. Fraunhofer IKTS provides measurement systems for customer-specific modules, which guarantee highest material compatibility between sensors and CFRP, also regarding curved components. Such a smart assembly enables a fast condition testing in the workshop and reduces both the efforts for disassembly and the downtime.

For more information on sensor integration, please contact:

Dr. Mike Röllig
Department: Testing of Electronics and Optical Methods, Group: Reliability of Microsystems

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© Fraunhofer IKTS
Sound pressure course during welding process.
© Fraunhofer IKTS
Spectrogram of valve monitoring with a dent in the valve seat.
© Fraunhofer IKTS
High-temperature product labeling of a component under UV light.

Processes

 

Condition monitoring in the production process

Condition evaluation of a production process starts with an acoustic process analysis, in which process-typical parameters are identified and correlated with acoustic measurement variables.
Measurement results are verified at Fraunhofer IKTS by means of metrologically accompanying the process and parallel controlling process characterizing parameters. Solutions for condition monitoring in the production process are offered for many branches and areas, e.g.:

  • Defect detection during joining in automobile engineering processes
  • Monitoring of welding processes
  • Analysis of high-volume production processes with miniaturized measurement technologies

For more information on condition monitoring, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Valve monitoring for compressors

Compressed air and vacuum technologies are used in nearly every industrial plant. For monitoring compressors and compressor units, superior control and remote diagnostic tools already exist, which concern the topic industry 4.0. Particularly the monitoring of valves of compressors is very complex due to manifold environmental parameters.

The valve monitoring system of Fraunhofer IKTS permanently monitors and evaluates the crucial components based on a combination of different sensors, e.g. pressure, acceleration, temperature and acoustic emission sensors. By means of specific data acquisition and analysis, periodic maintenance tasks are reduced considerably and preventive measures against material wear and other disturbing factors become possible.

For more information on valve monitoring, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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CeraCode® – component tracing in metal processing

The individual labeling (direct part marking) of heat-treated components in metal processing poses some challenges. In order to meet constraints defined by both materials and processes (high temperatures, coated surfaces), Fraunhofer IKTS developed the CeraCode® labeling technology based on robust ceramic luminescent materials. The technology allows for tracing components over the entire process chain.

For more information on CeraCode® labeling technology, please contact:

Dr. Thomas Härtling
Department: Electronics Testing and Optical Methods, Group: Optical Test Methods and Nanosensors

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3D vibration analysis for process optimization

In order to prevent a total failure of technological plants, Fraunhofer IKTS offers 3D vibration analysis as an on-site tool for contact-free measurements. It enables, e.g., for packaging machines, an early identification of vibration-causing weaknesses.

Three-dimensional vibration and modal analyses as well as 3D strain measurements are evaluated on-site. Due to a high spatial resolution, very small but also large plants can be monitored. The broad frequency range and the high resolution of the system allow for measurements of low-frequency vibrations with large deflections up to smallest high-frequency vibrations.

The simultaneous coverage of vibration components in all dimensions saves measurement time and cost compared to other measurement technologies (e.g. 1D vibrometer).

Fraunhofer IKTS offers 3D vibration analysis, among others, for the following applications:

  • Transducer characterization
  • Imaging of wave diffusion and damage interaction in various materials and structures

For more information on vibration analysis, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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3D dosemeter for the detection of high-energy radiation

The detection of the high-energy radiation dose (e.g. gamma or electron radiation) on curved 3D-freeform surfaces can be realized with the help of inorganic phosphors. The 3D dosemeter of Fraunhofer IKTS (measurement range 0–250 kGy, dose resolution up to 80 kGy: 1 kGy and from 80 kGy: 5kGy) optically reads out the dose information from arbitrarily formed surfaces with high spatial resolution.

For more information on the 3D dosemeter, please contact:

Dr. Thomas Härtling
Department: Electronics Testing and Optical Methods, Group: Optical Test Methods and Nanosensors

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© Fraunhofer IKTS
CoMoSens – sensor of the monitoring system CoMoRanger.
© Fraunhofer IKTS
CoMoDetect for crack and corrosion monitoring regarding containers.
© Fraunhofer IKTS
Wireless sensor nodes for high- and low-frequency monitoring tasks.

Plants and systems

 

CoMoRanger – monitoring of corrosion-susceptible components

CoMoRanger can be used to monitor pipes, which are difficult to access, and other corrosion-susceptible components in technical plants. A particularity of the system consists is the continuous determination of the residual wall thickness in case of an extensive corrosion.

For more information on the CoMoRanger, please contact:

Dr. Bianca Weihnacht
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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CoMoDetect – certified monitoring system for large containers

For monitoring large containers, as used in chemical plants or refineries in explosion-proof areas, Fraunhofer IKTS provides a certified solution with CoMoDetect. It permanently monitors inaccessible containers and other corrosion-susceptible components for cracks and corrosion. With CoMoDetect, maintenance conditions of plants can be determined during production.

For more information on CoMoDetect, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Self-sufficient monitoring system for wireless structural diagnostics

Wireless sensor nodes are designed for high- and low-frequency monitoring tasks with a corresponding energy supply system for structural monitoring of technical plants, such as bridges or dams. This is especially advantageous regarding locations which are difficult to access and decoupled from energy supply, or for EMC-sensitive applications. In addition, the monitoring system is the better alternative for fast inspections, when cable installation would consume too much time.

For more information on the self-sufficient monitoring system, please contact:

Uwe Lieske
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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Test systems for evaluation of fatigue level of ferromagnetic components

Fraunhofer IKTS offers a test system for the evaluation of fatigue levels of large-scale industrial plants and buildings. Hence, residual stress and materials conditions as well as hardness of ferromagnetic materials can be determined on-site and material damage realistically assessed.

For more information on the evaluation of the fatigue level here:

Susanne Hillmann
Department: Accredited Test Lab

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Acoustic pattern recognition for automatic evaluation of test objects

Acoustic pattern recognition is applied for an automatic evaluation of test objects. The measurement result is automatically classified in ”good”/”bad” or ”new”/”attrited”/”defect”. The adaptive and problem-independent approach is suitable for every acoustic diagnosis, needs little or no a-priori knowledge and allows for a combination of many sensor data by data fusion. Its capabilities comprise the detection of cracks, inclusions, impacts and deterioration, the monitoring of production processes, monitoring of wear level of machines as well as the condition monitoring of components, materials, machines and entire plants. An evaluation of non-technical (speech, music, biosignals) signals is also possible.

For more information on acoustic pattern recognition, please contact:

Dr. Constanze Tschöpe
Department: Bio- and Nanotechnology, Group: Acoustical Diagnostics

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Monitoring systems for rail vehicles and tracks

Rail vehicles and tracks are subject to critical stress. A self-sufficient measurement system monitors rail vehicles and their components, such as springs, bearings and brakes. In addition, the loading of rail vehicles can be monitored. Applications are possible both in transportation of passengers and goods as well as in trams.

For the monitoring tracks, Fraunhofer IKTS offers a monitoring system based on high- and low-frequency solid-borne sound sensors. This system solution including signal processing and integrated wireless data transfer (bluetooth) is energy self-sufficient.

For more information on the monitoring systems, please contact:

Dr. Lars Schubert
Department: Smart Materials and Systems, Group: Systems for Condition Monitoring

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