Fraunhofer Group for Microelectronics in cooperation with the Leibniz institutes IHP and FBH
Fraunhofer Group for Microelectronics in cooperation with the Leibniz institutes IHP and FBH
Simmering
© Fraunhofer ENAS
Simmering

© Fraunhofer ENAS

Sensor systems for process and condition monitoring

Modern factories are only profitable if they function flawlessly and can produce without disruption. Rejects and downtime quickly cause enormous consequential damage in production due to unplanned downtime or concealed production errors. An unnoticed tool breakage or faulty production system is often enough to cause this.

Sensor-based monitoring of production resources is an essential component in avoiding this. Equipping various objects, such as plants, robots, or conveyors and storage systems, with sensors enables targeted data and information acquisition and communication between the objects themselves. In this way, capacity utilization, as well as the operating and maintenance status of key machine components, can be recorded in real-time and communicated to higher-level planning and control systems. Sensor solutions not only monitor machine and process statuses but also production resources such as grease, oil, or air quality. Production damage or unnecessary machine downtime can thus be avoided.

Fields of research:

  • Wireless sensor systems
  • Sensor systems for extremely harsh environments
  • Zero-power sensors
  • Sensor platforms
  • Sensor data transmission

Project examples

Intelligent diagnostic interfaces for networked IoT systems @ Fraunhofer EMFT

Researchers at Fraunhofer EMFT are working on so-called Cyber Physical Connectors, a new generation of active, "intelligent" connectors, in a project of the same name. 

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Energy-efficient neuromorphic computing - e.g. for processing sensor data, predictive maintenance or condition monitoring in Industry 4.0 @ Fraunhofer EMFT

Within the EU project NeurONN, a Fraunhofer EMFT research team is working with six European partners on extremely energy-efficient elements and architectures for neuromorphic computing. Innovative 2D materials are also being used in the process.

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Hybrid and Wireless Sensors and Systems @ Fraunhofer ENAS

The focus of research and development is on holistic solutions for the areas of smart farming (environmentally friendly sensors) and smart power (monitoring of supply networks, wireless power supply to sensor and actuator systems) as well as structurally integrable, wireless sensor systems for industrial applications and the digitalization of production (smart production).

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Structure-integrated, wireless sensors and actuators in mechanical engineering (SdSeMa) with Fraunhofer ENAS, Fraunhofer IIS/EAS, Fraunhofer IPMS, Fraunhofer IZM-ASSID

In the project SdSeMa of the High-Performance Center "Functional Integration for Micro- and Nanoelectronics", the institutes Fraunhofer ENAS, IIS/EAS, IPMS, and IZM/ASSID, with assistance of Fraunhofer IWU and Fraunhofer IKTS, worked on new technologies for the structural integration of sensors and actuators in machine components. 

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Active workpiece carrier with Fraunhofer ENAS

In close cooperation with the University of Paderborn, a wireless technology was developed which enables a workpiece carrier to adapt itself mechanically and logically to the next product variant within the production cycle time.

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Wireless sensor systems for the flexible design of production processes with Fraunhofer ENAS

The goal of the BMBF project "DiSSproSiP" was the automation and individualization of industrial production systems in the form of a wireless, intelligent sensor system. 

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Optical monitoring system for quality control of electroplating solutions with Fraunhofer ENAS

In a joint project, Fraunhofer ENAS and Japanese enterprise SHINKO ELECTRIC INDUSTRIES CO., LTD. have developed an optical sensor system in order to have a cost efficient online quantification of essential ingredients of electroplating solutions. 

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Wireless sensor systems for structural health monitoring with Fraunhofer ENAS

To support the industry with smart production technologies a radio frequency identification transponder (RFID tag) for a structural health monitoring application of industrial rubber belts was developed. 

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Printed antennas on cardboard boxes for the identification of metal objects in supply chains with Fraunhofer ENAS

The aim of the reported project was to optimize the warehouse and transport logistics to save costs. In order of wireless identification Radio Frequency Identification (RFID) transponders are attached to the items to be traced.

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ENIAC project ESEE - Oxygen measurement for cavity-expanded mm-wave with Fraunhofer ENAS

A cavity enhanced millimeter-wave absorption spectrometer for oxygen concentration measurement was developed in the framework of the ENIAC project ESEE (Environmental Sensors for Energy Efficiency) together with partners from Airbus, Infineon and the Friedrich-Alexander University Erlangen-Nürnberg. 

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Functional safety @ Fraunhofer ENAS

Industry 4.0 means highly connected production with communication across the full value chain. It requires smart systems to provide the capabilities of sensing, data processing, data interpretation and communication. Even under harsh industry environments, these smart systems must be very reliable. 

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eHarsh: Sensor systems for extremely harsh environments, proof of concept for CMUT signal performance with Fraunhofer ENAS

Within the framework of Fraunhofer’s lighthouse project “eHarsh”, Fraunhofer ENAS is investigating the feasibility of using Capacitive Micromachined Ultrasound Transducer (CMUT), which can operate at high temperatures (due to its non-piezo based structure),  for borehole imaging.

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Checking thickness of steel sheets with radar @ Fraunhofer FHR

In collaboration with IMS Messsysteme GmbH, Fraunhofer FHR has developed the first thickness measurement system based on radar sensor technology for hot rolling and heavy plate mills.

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FiberRadar @ Fraunhofer FHR

With the "FiberRadar" project, Fraunhofer FHR, together with the consortium partners Ruhr-Universität Bochum, Aachen University of Applied Sciences and Aeroconcept GmbH, is developing a novel method for controlling the manufacturing process of high-strength fiber composites.

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ASRA - Adaptive control of steel strips in hot rolling mills based on high-precision radar signal processing methods

 In order to sustainably increase production efficiency, IMS Messsysteme GmbH, SMS Group GmbH, IMST GmbH, Ruhr-Universität Bochum and Fraunhofer FHR are cooperating within the "ASRA" project to implement using radar methods to measure the contour of the edge of the rolling stock within a hot rolling mill for the first time.

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With plenty of Hertz for production @ Fraunhofer FHR

Fraunhofer FHR conducts research into innovative sensors for quality control in real time. Fast measuring speeds in combination with the ability to perform high-precision measurements even under the most adverse environmental conditions are the most important hallmarks of high-frequency systems for industrial applications

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Radar sensors increase efficiency in production and automation @ Fraunhofer IAF

The Fraunhofer Institute for Applied Solid State Physics IAF develops compact and high-resolution radar systems, which can significantly increase the efficiency of different industrial processes. 

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Digital status tracking for products or picking systems @ Fraunhofer IPMS

Li-Fi Optical Data Transmission and IP-Core Design for FPGA and ASIC.

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Machine vision for quality assurance - multidimensional sensor technology @ Fraunhofer IPMS

A Fraunhofer IPMS research team is pursuing the approach of a "scanning eye", which is intended to enable machine vision in three dimensions. The scanning mirror module functions as a scanning eye that can record high-resolution images in all three spatial axes.

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Fraunhofer Institutes help small and medium-sized enterprises to develop innovative ultrasonic sensors with Fraunhofer ENAS, Fraunhofer IPMS, Fraunhofer ISIT

As part of the development of the MUT platform, priority will be given to three central SME research fields: production technology, human-machine interaction and medical technology. 

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Application-specific service life assessment I Robustness and service life assessment @ Fraunhofer IZM

Fraunhofer IZM's primary task is to control the management activities for achieving reliable products and processes throughout the entire product lifecycle. Ensuring reliability starts within the innovation phase. 

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Lifetime monitoring of IGBT modules @ Fraunhofer IZM

IGBT (Insulated Gate Bipolar Transistor) power modules are the key component in modern inverters for photovoltaic systems. Unforeseen failures of the modules and therefore of the PV system can be reliably avoided by monitoring their condition and making service life predictions based on this, thereby increasing the availability of the system and its maintenance intervals.

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Fraunhofer researchers develop high-pressure sensors for extreme temperatures @ Fraunhofer IZM

Many industrial processes depend on exact pressure gauges. The SOI high-pressure sensors (silicon-on-insulator) developed by the Fraunhofer Institute for Reliability and Microintegration IZM makes this exact monitoring possible for processes operating at temperatures of up to 400° centigrade.

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