Structure-integrated, Wireless Sensing in Tools and Machinery

Digitalization is considered the key to unlocking optimization potential in production processes. The vision is a self-organizing, user-centered, and demand-driven production system that ensures high competitiveness—even in volatile environments. The analysis of process and machine data allows for the optimization of resource and material consumption, improved production quality, and increased system availability and safety.

Direct signal acquisition from drives, tools, and workpieces enhances data density and quality, enabling real-time process optimization—far beyond what is possible with indirect estimations and cloud-based data analytics. To achieve this, sensors, actuators, and the associated miniaturized components for energy-efficient data transmission must be directly integrated into the structures of drives or tools.

In collaboration with the High Performance Center "Smart Production Materials", we design, develop, and test solutions for integrating sensors and actuators into machinery. One example is the integration of a sensor ring into a ball screw drive. The smart features of the sensor ring enable in-operation monitoring of wear. As a result, maintenance and replacement can be scheduled based on actual need—reducing downtime and cutting costs.

The following technologies were implemented, all of which can be transferred to various other applications:

• Full structural integration (micro/nano) of all core components through consistent miniaturization
• Flexible form factors to adapt to limited installation space using flexible substrates and connectors: 
  • Flexible printed circuit boards (FPCs)
  • Flexible printed circuit connectors
  • Rigid-flex wafer-level packages for ultra-small bending radii (foldable designs)
• Modular concept comprising units for power supply, sensing, data processing, and communication
  • Wireless energy transfer for battery recharging
  • Sensor suite including temperature, acceleration (vibration, orientation), force (strain gauge-based), acoustics (MEMS microphone), and digital interfaces (UART, SPI, I²C, GPIO) for additional sensors
  • Edge data processing with local data storage capability (data logger function)
  • Wireless data transmission from shielded metallic environments via Bluetooth, NFC, or LiFi, depending on application requirements

Are you interested—or do you have ideas on how to equip your machinery with intelligent features using advanced micro-/nanoelectronics and microsystems technologies? Feel free to get in touch with us.

Your Benefits/Our Offer:

For Component Manufacturers (e.g., mechanical engineering, automation technology):

• Comprehensive consulting on component digitization – from business case analysis to technology selection
• Development and commissioning of prototypes
• Validation in both lab and real-world environments

For Sensor Manufacturers:

• Support in exploring new application areas
• Prototyping for the integration of sensor components into intelligent systems