Smart Gears Featuring Prognostics as Integrity-Loss Detector

• Project/Area Number: 16H04258
• Research Category: Grant-in-Aid for Scientific Research (B)
• Allocation Type: Single-year Grants
• Section: 一般
• Research Field: Design engineering/Machine functional elements/Tribology
• Research Institution: Kyoto Institute of Technology
• Principal Investigator: MORIWAKI Ichiro 京都工芸繊維大学, 機械工学系, 教授 (20157936)
• Co-Investigator(Kenkyū-buntansha): 射場 大輔 京都工芸繊維大学, 機械工学系, 准教授 (10402984) ; 曽根 彰 京都工芸繊維大学, 機械工学系, 教授 (20197015) ; 三浦 奈々子 京都工芸繊維大学, 機械工学系, 助教 (80735340) ; 増田 新 京都工芸繊維大学, 機械工学系, 教授 (90252543) ; 飯塚 高志 京都工芸繊維大学, 機械工学系, 准教授 (60335312) ; 中村 守正 京都工芸繊維大学, 機械工学系, 准教授 (00464230)
• Project Period (FY): 2016-04-01 – 2019-03-31
• Project Status: Completed (Fiscal Year 2018)
• Budget Amount: ¥17,810,000 (Direct Cost: ¥13,700,000、Indirect Cost: ¥4,110,000); Fiscal Year 2018: ¥1,430,000 (Direct Cost: ¥1,100,000、Indirect Cost: ¥330,000); Fiscal Year 2017: ¥4,810,000 (Direct Cost: ¥3,700,000、Indirect Cost: ¥1,110,000); Fiscal Year 2016: ¥11,570,000 (Direct Cost: ¥8,900,000、Indirect Cost: ¥2,670,000)
• Keywords: 損傷検知 / スマートギヤ / 導電性インク / 印刷センサ / 故障診断 / レーザー焼結 / ４軸印刷機

Outline of Final Research Achievements

The present study initiated the development of a system for printing sensors and antennas with conductive ink to realize smart gears, which enable their own integrity to be wirelessly monitored during their operation. First of all, a 4-axis laser printer was developed for printing circuits directly on gears. After some crack-detection sensors were designed, running tests were carried out on gears printed the sensors. The results showed that the resistance of the sensors increased with the increased in mesh cycles. Furthermore, designed were an open spiral antenna and an antenna-sensor system which consists of the antenna and the sensor. The printed antenna and antenna-sensor system were evaluated through the measurement of return
losses. The results showed that the resonance property depends strongly on the presence of cracks.

Academic Significance and Societal Importance of the Research Achievements

情報化社会の発展を支える無線通信機器の技術開発は凄まじい速度で進められており，IoTを駆使したSociety 5.0といわれる世界の実現が目前に迫っている印象がある．ところが，非常に厳しい環境で利用される歯車などの機械要素の状態を直接観測するためにこうした通信の技術が利用された例はなかった．その理由として，形状に制約を有する機械要素にアンテナやセンサを直接形成する技術が存在していなかったことなどが挙げられる．本研究では，その技術課題を明確にし，歯車の状態をワイヤレスで監視するシステムの基礎を確立した．この成果は，まだ僅かではあるが，Society 5.0の具現化に寄与するものである．

Research Products

• [Journal Article] Development of smart gear system by conductive-ink print (impedance variation of a gear sensor with loads and data transmission from an antenna) (2019)
  • Author(s): 1.Daisuke Iba, Shintaro Futagawa, Nanako Miura, Takashi Iizuka, Arata Masuda, Akira Sone, Ichiro Moriwaki
  • Journal Title: Proc. SPIE 10973, Smart Structures and NDE for Energy Systems and Industry 4.0 Volume: 1097309 Pages: 8-8
  • DOI: 10.1117/12.2515339
• [Journal Article] 2.Fabrication of antennas on spur gears for condition monitoring by conductive-ink print (2018)
  • Author(s): S. Futagawa, D. Iba, T. Kamimoto, M. Nakamura, N. Miura, T. Iizuka, A. Masuda, A. Sone, I. Moriwaki
  • Journal Title: Proceedings of International Gear Conference Volume: － Pages: 1418-1426
• [Journal Article] Printed gear sensor for health monitoring (Development of three-axis laser printer for conductive ink and evaluation of laser-sintered electric circuits) (2017)
  • Author(s): Daisuke IBA, Shintaro FUTAGAWA, Takahiro KAMIMOTO, Morimasa NAKAMURA, Nanako MIURA, Takashi IIZUKA, Arata MASUDA, Akira SONE, Ichiro MORIWAKI
  • Journal Title: Journal of Advanced Mechanical Design, Systems, and Manufacturing Volume: 11 Issue: 6 Pages: JAMDSM0090-JAMDSM0090
  • DOI: 10.1299/jamdsm.2017jamdsm0090
  • NAID: 130006267903
  • ISSN: 1881-3054
  • Peer Reviewed / Open Access
• [Presentation] 導電性インク印刷技術を用いた歯車用センサシステムの開発 (歯車表面に印刷されるアンテナの設計) (2018)
  • Author(s): 二川 真太郎，射場 大輔，三浦 奈々子，飯塚 高志，増田 新，曽根 彰，森脇 一 郎
  • Organizer: 2018年度日本機械学会年次大会
• [Presentation] 導電性インク印刷による回路形成技術を用いた歯車用センサ開発 (プラスチック歯車側面に印刷したき裂検知センサの特性評価) (2018)
  • Author(s): 二川 真太郎，射場 大輔，神本 貴裕，市川 嵩人，三浦 奈々子，飯塚 高志，増田 新，曽根 彰， 森脇 一郎
  • Organizer: 日本機械学会機素潤滑設計部門講演会
• [Presentation] Conductive ink print on PA66 gear for manufacturing condition monitoring sensors (2018)
  • Author(s): Shintaro Futagawa, Daisuke Iba, Takahiro Kamimoto, Morimasa Nakamura, Nanako Miura, Takashi Iizuka, Arata Masuda, Akira Sone, Ichiro Moriwaki
  • Organizer: SPIE 10602, Smart Structures and NDE for Industry 4.0
  • Int'l Joint Research
• [Presentation] Development of sensing systems printed with conductive ink on gear surfaces: manufacturing of meander line antenna by laser-sintered silver nano-particles (2017)
  • Author(s): D. Iba, S. Futagawa, T. Kamimoto, N. Miura, M. Nakamura, T. Iizuka, A. Masuda, A. Sone, I. Moriwaki
  • Organizer: Proc. SPIE 10168, Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems 2017
  • Place of Presentation: Portland, Oregon, USA
  • Year and Date: 2017-03-25
  • Int'l Joint Research
• [Presentation] DEVELOPMENT OF PRINTED SENSOR FOR GEAR HEALTH MONITORING SYSTEM (DEVELOPMENT OF THREE-AXIS PRINTER FOR CONDUCTIVE INK LASER SINTERING PROCESS AND PROPERTIES EVALUATION OF SINTERED ELECTRIC CIRCUIT) (2017)
  • Author(s): Takahiro KAMIMOTO, Daisuke IBA, Shintaro FUTAGAWA, Morimasa NAKAMURA, Nanako MIURA, Takashi IIZUKA, Arata MASUDA, Akira SONE, Ichiro MORIWAKI
  • Organizer: The JSME International Conference on Motion and Power Transmissions (MPT 2017 - Kyoto)
  • Place of Presentation: 京都
  • Year and Date: 2017-03-01
  • Int'l Joint Research
• [Presentation] Print of crack detection sensor for spur gears by laser sintering of conductive ink (2017)
  • Author(s): D. Iba, S. Futagawa, T. Kamimoto, M. Nakamura, N. Miura, T. Iizuka, A. Masuda, A. Sone, I, Moriwaki
  • Organizer: International Conference on Gears 2017
  • Int'l Joint Research
• [Presentation] POM製平歯車側面への導電性インクの印刷によるき裂検知センサの製作 (2017)
  • Author(s): 二川 真太郎, 射場大輔，神本貴裕，中村守正，三浦奈々子，飯塚高志，増田新，曽根彰，森脇一郎
  • Organizer: 日本機械学会2017年度年次大会
• [Presentation] Development of 3-axis laser printing system for manufacturing smart gear sensor systems (printing conditions by laser sintering and prototyping of meander line antenna) (2016)
  • Author(s): D. Iba, R. Rodriguez Lopez, S. Futagawa, T. Kamimoto, M. Nakamura, N. Miura, T. Iizuka, A. Masuda, A. Sone and I. Moriwaki
  • Organizer: International Conference on Advanced Materials, Mechanics and Manufacturing
  • Place of Presentation: Hammamet, Tunisia
  • Year and Date: 2016-12-19
  • Int'l Joint Research
• [Presentation] 導電性インクのレーザー焼結によるインボリュート曲線の印刷 (2016)
  • Author(s): 神本貴祐, 射場大輔, 二川真太郎, 中村守正, 三浦奈々子, 飯塚高志, 増田新, 森脇一郎, 曽根彰
  • Organizer: 第15回評価・診断に関するシンポジウム
  • Place of Presentation: 京都
  • Year and Date: 2016-12-15