Springing Forward into Industry 4.0: Exploring Cutting-Edge Research at Smart Pneumatics Lab

In the vibrant landscape of industrial innovation, Smart Pneumatics Lab stands as a beacon of progress, pioneering advancements at the intersection of technology and manufacturing. Like a coiled spring ready to unleash its potential, our laboratory is committed to unraveling the complexities of Industry 4.0.

1. Predictive maintenance on conveyor

In a recent meeting, we delved into the intricacies of four groundbreaking research projects poised to redefine the industrial landscape. One project focuses on a mechanical conveyor system interwoven with an array of sensors, paving the way for predictive maintenance strategies that optimize operational efficiency and minimize downtime.

We have designed a conveyor system to be powered by our Aventics Cylinders by a pinion-rack system going back and forth. This way we can have a heavy load going along the whole conveyor. This load with put wear on the bearings, on the rollers, on the pinions, on the belts etc.

We will use A LOT of sensors along side the IOTIA predictive maintenance app to see HOW each part will degrade over time.

Also, the actuating equipment will also be kitted out with sensors. From pressure sensors to vibration sensors to see if tubes are cut or to see if bearings need to be changed.

2. Simulation vs Real Life

Another endeavor explores the dynamic realm of Computational Fluid Dynamics (CFD) simulation versus real-world simulation, illuminating the nuances and benefits of each approach in industrial contexts.

Our team, Ivan Codrin and Robert Ifrim, has taken on the important task of exploring the subject of energetic efficiency in pneumatic systems.

We started by doing some research that would give us a brief idea of what we were getting ourselves into. The approach we decided on was crucial for the outcome of our research and after further discussions with our teammates, we agreed that the most suitable way to find the energetic efficiency of a whole system would be to take the main components it was made out of and put them to test by using pneumatic sensors and the equipment of our laboratory.

Using the results of the real-life experiment, we will correlate them and put them in comparison to simulations in specialized CFD (computational fluid dynamics) software, so that the combination of the two could help us trace common energy loss causes and methods we can use in order to minimise them.

3. MPU6050 Accelerometer vs Magnetic Linear sensor for vibration analysis on Pneumatic Cylinders

Meanwhile, our investigation into the disparity between linear sensors and accelerometers for vibration analysis promises to unearth invaluable insights into machinery health monitoring, offering clarity amidst the noise of industrial operations.

Sensors play a crucial role in monitoring the behavior of various applications. Two commonly used sensors are the linear position sensor and the accelerometer. While both of these offer a valuable insights, they differ in key aspects, making them more suitable for different uses.

A linear position sensor directly measures the distance of an object relative to the initial position along a single axis, without any additional noise. The acceleration can be calculated from these precise movement differences, offering a high accuracy. By knowing this, the linear sensor is well suited for predicable and controlled environments.

An accelerometer measures the acceleration of an object in each one of the 3 axis. This makes it excellent at detecting rapid movements, and vibrations, making them ideal for dynamic situations. The accelerometers have a higher polling rate than the linear position sensor, that cause them to have a higher noise in readings. Furthermore, they need to be calibrated before using them, while the linear position sensors don’t need to.

4. AllDay: Productivity measurement and sensor availability tool

Lastly, we delve into the realm of human-machine interaction with an innovative application designed to monitor personnel productivity, streamline meeting scheduling, and ensure the seamless operation of MQTT sensors throughout our laboratory environment.

Starting as a small, over the winter break project, the local WI-FI tracker is now the subject of a case study, regarding the power of locally transmitted information packages. The base concept is centred around how one can determine who is connected to the local network and what can be done with that information.

The project was divided into two smaller appliances, first of which is now ready and working, a presence tracker website with smart data analysis called AllDay. Users create an account which will allow them to see who is present in the router’s proximity at any time and then can analyze metrics such as: productivity, best hours for meetings, presence in the past and much more.

The next, more ambitious, project will build on the base AllDay created, making it a software offering centralized data gathering and instantaneous maintenance for any IIoT device available in the workspace.

As we embark on this journey of discovery, Smart Pneumatics Lab remains dedicated to pushing the boundaries of technological possibility, driving progress, and catalyzing transformation in the realm of Industry 4.0.