A Reliable Wireless Sensor System for Monitoring Mechanical Wear-Out of Parts

A ball screw is a typical mechanical part that experiences wear-out and is widely used in computer numerical control machine tools to control the movement of processing targets and spindles. These types of parts need frequent checks so that they are replaced before excessive wear occurs. Until now, there was no simple way to measure directly the state of wear quantitatively. An indirect approach is logging the signals (vibration, temperature, and preload change) during the operation of mechanical parts. This information can be used to construct a wear model for estimating its remaining lifetime. For embedding sensors into mechanical devices, wireless sensors bring advantages in that they may be installed freely without constraints from data or power cables. However, wireless transmission is subjected to interference. To make wireless sensors that can be used practically within an industrial environment, we propose a wireless sensor system that: 1) emphasizes low-power and low cost in hardware design; 2) logs the signals during the operation of a mechanical part that could experience wear; and 3) guarantees that all the logged data can be wirelessly delivered to the data server. To our knowledge, this is the first wireless sensor system for measurement of mechanical operation signals that guarantees complete data delivery and correctness. We designed, implemented, and evaluated this system in real environments. This ensures that the design is practical. We envision that a miniature version of our design could be embedded in the ball screw shaft and gearbox reducer for logging signals to enable the building of a wear model to estimate the part's lifetime.