Wireless WiFi temperature measurement box for safe, precise and flexible process monitoring in rotating applications

Designed for use in rotating hardening processes, SPIE AUTOMATION developed a compact, wireless measurement solution that solves key safety and handling issues and ensures reproducible results under real production conditions.

Challenge and Objective

The customer’s initial situation presented the developers at SPIE AUTOMATION with a demanding task: a solution was needed for precise temperature measurement of a test cam within a hardening station. The methods used up to that point proved impractical and critical from a safety perspective, as the measuring equipment was located outside the system and the temperature measurement leads had to be carried along during rotating operation.

The aim of the project was therefore to develop a compact, wireless and steam-tight temperature measurement box. It was to work directly on the cam with two temperature sensors, be suitable for use in rotating applications without cabling, and store the measurement data in CSV format. In addition, wireless data transmission and operation were required. Temperature acquisition was to be performed at a sampling rate of 10 Hz. Particular challenges arose from the operating conditions in the hardening station: aggressive cooling water, steam generated during the cooling process, and workpiece temperatures of up to 1100°C.

Solution

The project was implemented by the experienced SPIE AUTOMATION team, consisting of specialists in mechanical engineering, electronics and software development. In summary, the development process can be divided into the following phases:

Feasibility study and concept phase: In a proof-of-concept phase, it was examined whether the technical requirements were feasible. Initial prototypes confirmed the feasibility of the wireless temperature measurement system.
Design and development phase:
- Mechanical design: A compact housing was developed that is water- and steam-tight and enables use in rotating operation.
- Electronics and software: Modular electronic components were integrated to reduce development time and costs. This made it possible to avoid designing a complex PCB.
- Data transmission: A wireless WiFi module was integrated that transmits the measurement data in real time.
Challenges and solution:
- Rotating application: A wireless connection and a stable power supply were ensured despite the rotating environment.
- Prototype collision: After completion of the first housing prototype, the customer found that it collided with the system. This required a redesign in which the installation space had to be reduced by 70% without restricting functionality.

Benefits

The new WiFi temperature measurement box offers numerous advantages:

Easy handling: The compact box is easy to install and operate.
Increased safety: Thanks to the wireless design, no measurement leads need to be carried along in the rotating application.
Quality assurance: Reliable logging of the hardening process optimizes product quality.

The customer was very satisfied with the solution and particularly praised the high flexibility and the competent project implementation despite unexpected challenges.

These SPIE AUTOMATION Strengths Were Applied

About our customer
Our customer is an internationally leading automotive supplier focused on innovative components and systems for the powertrain. With decades of experience, the company is one of the established partners of the automotive industry worldwide and stands for technologically sophisticated solutions.

Industry
Automotive supplier

Despite the challenges and the redesign, we were able to find good solutions and implement all requirements without compromise. The customer also gave us positive feedback and is very satisfied with the solution.