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Sensor-Integrated Couplings by R+W – Data as the Key to Greater Efficiency

Precise data is the foundation for informed decision-making in the development of new machines and systems. Whether it’s for the dimensioning of drive components, the validation of simulations, or the optimization of existing systems—accurate monitoring of physical operating parameters is essential. In particular, test benches benefit greatly from precise measurements during realistic load testing. An often underestimated but highly valuable source of data is the coupling itself. Positioned directly within the power flow, it allows for high-precision measurements exactly where critical mechanical loads occur.

Couplings are essential components of the drive train. When equipped with integrated sensors, they not only compensate for misalignments and transmit torque, but also record crucial operating parameters. Their direct integration into digital monitoring systems opens up new possibilities for industrial applications. Instead of relying on difficult-to-integrate external measuring systems, data can now be captured directly at various points within the drive train. Torque, speed, and temperature are monitored in near real-time, enabling more precise control of machines and systems. Especially in the context of predictive maintenance or optimal system dimensioning, real load data is indispensable. Sensor-integrated couplings measure directly in the power flow, delivering precise values that help avoid overengineering, detect potential weaknesses early, and allow maintenance measures to be planned based on actual need rather than fixed intervals.

The Challenge: Integrating Sensors into the Drive Train

Measuring physical variables within a drive train presents several challenges. External sensors require additional components, wiring, and sometimes structural modifications—leading to space constraints and increased costs. Their installation and configuration often require specialized personnel, which further complicates commissioning. Moreover, external influences such as vibrations or temperature fluctuations can distort measurement results.

R+W addressed these challenges by developing a sensor-integrated coupling that combines mechanical performance with digital sensing technology. The concept, initiated back in 2019, aimed to create a coupling that not only transmits torque and compensates for misalignments but also serves as a measurement tool. In alignment with the goals of Industry 4.0, smart factories, and resource-efficient manufacturing, this product offers real added value for machine operators.

The Solution: Sensor Technology Integrated into the Coupling

The technological breakthrough was achieved through the integration of a specially designed deformation body inserted into a hollow cylindrical component using a patented press-fit process. This design enables the highly precise detection of mechanical deformations, which are converted into measurement values.

At the core of the coupling lies a highly sensitive system consisting of strain gauges, a measurement amplifier, and a Bluetooth antenna for wireless, near real-time data transmission. The entire electronic system is compactly housed within the coupling and is powered by a rechargeable battery or via inductive charging. This eliminates the need for external cables or complex modifications to the drive train.

This level of integration ensures that the coupling can be seamlessly incorporated into existing drive systems without requiring additional space or compromising mechanical functionality. The sensors continuously collect measurement data and transmit it to higher-level control systems. This enables early detection of sudden load spikes or initial signs of wear.

Wide Range of Applications Across Industries

Sensor-integrated couplings are valuable tools for research and development, supporting the validation of drive concepts and more precise dimensioning of mechanical components. They help avoid unnecessary safety margins and enable continuous monitoring of system health. Companies benefit from improved machine availability, as maintenance can be performed based on actual conditions rather than rigid schedules. This reduces downtime risk and enhances process efficiency. Moreover, the data collected offers insights into potential failures in other components. Early analysis allows targeted countermeasures before major damage occurs.

Looking Ahead: Standardized and Modular Solutions

With the introduction of the new iPK model series, R+W has advanced this technology by creating a standardized solution that offers high flexibility, compact design, and modular adaptability. Thanks to a mix-and-match concept using a newly developed flange, the sensor-integrated coupling can be reused across various applications and easily customized to specific requirements.

To ensure compatibility with the “R+W modular system,” the series has been designed for integration with bellows, elastomer, disc, and safety couplings. The modular construction enables easy replacement or expansion of components. Additionally, the bolted connection allows for quick assembly and disassembly, which is especially advantageous for maintenance or equipment reconfiguration.

These features make sensor-integrated couplings not only a technological innovation but also an economically sound investment. They increase operational safety, reduce costs, and contribute to more sustainable industrial production.

Conclusion: Couplings as the Data Collectors of the Future

With its sensor-integrated coupling, R+W has taken a major step toward smart drive technology. The fusion of mechanical functionality and intelligent sensing makes this technology a game changer for digital transformation in mechanical engineering. Companies looking to optimize their processes and advance toward Industry 4.0 now have access to an innovative, practical solution.

Pictures:

Figure 1: The modular design with a sensor-integrated intermediate flange allows the attachment of various coupling variants (shown here: disc coupling with split hub and safety coupling)

Figure 2: Data acquisition and misalignment compensation in a single product