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Project: Bottle Capping

A pharmaceutical company has a line dispensing and capping bottles with anesthetic fluid. The capping mechanism works on fast moving bottles, and had no means of being set to the appropriate capping force. Bottles either leaked, or caps broke.


Solution; SensorData offered a turn-key system consisting of a wireless Torque-Thrust sensor, a data acquisition hub, and data analysis software. Capping torque and thrust signals are wirelessly transmitted to the hub. A computer connected to the hub uses custom-developed software to process the data and monitor the optimum operating values of the capping parameters.

Project: Conveyor Real-Time Diagnostic System

A major car manufacturer had a persisting problem of very costly conveyor down times. The technology available then would only monitor the pull (Fz) in the conveyor. Measured values were stored in a memory chip on board for later download. Hence this technology would only be able to capture the value after failure occurs. More often conclusions by that technology were not accurate. It was found that most conveyor failures are due to bending moments rather that the pull in the line.M411-SENSORDATA

Solution: SensorData developed a turn-key system consisting of a 4-component link shaped wireless sensor, a remote transceiver, and processing software. Dynamic forces (Fz, Mx, My, Mz) measured by the sensor are wirelessly transmitted to the tranceiver. A computer with residing software processed the forces, calculated the resulting combined stresses, and compared instantaneous combined stresses with predetermined maximum allowable values. Because critical parameters were monitored in real time, it was possible for the first time to predict and mitigate a failure before it takes place.

Two US patents were obtained on this system.

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Sample of the data collected by the SensorData’s Conveyor Real Time Diagnostic System

Project: Positioning patients for Gama Rays Treatment

A medical equipment manufacturer needed to position a patient very accurately under a Gama ray source. The balancing of the patient lying on the table was very critical.

Solution: SensorData offered a 6-Component sensor to be placed under the gurney. Forces and moments sensed by the sensor would be fed to the robot controls for patient balance calculations.

Project: Conveyor Track Wear Monitor System

Expensive conveyor downtimes are usually attributed to either excessive force due to component mal-function, or to track excessive wear. Usually track wear was measured manually by calipers at different locations. Access to these locations is understandably cumbersome, dangerous and very time consuming. A major auto manufacturer commissioned SensorData to develop a system to automate this process.Screen Shot 2015-06-01 at 9.26.13 PM

Solution: SensorData developed an automated laser profile measurement system. The system accurately records profiles of conveyor track flanges (prone to wear) at as many predetermined locations as needed and stores these profiles into memory cards. At the end of one full turn of the conveyor, data is retrieved and analyzed by a specially developed algorithm identifying areas of normal, marginal and excessive wear.

What used to take several days of measurements the traditional old way, now hardly takes minutes (the time to complete a full conveyor cycle) thanks to this state of the art technology development. One can imagine the tremendous time and cost saving of this system.

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Data sample from a simulated conveyor track wear

Project: Fasteners Characteristics under Transverse Loading

A local university prestigious fasteners lab needed some equipment to study the behavior of fasteners under transverse vibration conditions according to DIN 65151. The lab is involved in testing of crucial components for the military, automotive and wind turbine industries and produces high caliber post graduate research on the topic.

Available equipment would either be limited to a narrow size/type of fasteners, or fall short of the number of parameters to be measured.

Solution: SensorData was consulted to design and build a lab quality lest rig which overcomes shortcomings of the state of the art.

The resulting product was a machine that can apply different levels of transverse vibrations to a wide range of fasteners at different amplitudes and frequencies while recording both tightening force on fastener and the transverse load applied.

Project: Connecting Rod Bolt Loosening

A German automotive component manufacturer experiencing bolt loosening of some connecting rods was referred to SensorData for help.

Solution: After studying the possible causes of the problem, our engineers identified the most probable ones and designed some complicated fixturing tools to reproduce the loosening phenomena. The most likely culprit was buckling and/ or bending of the connecting rod. Once the loosening was consistently reproduced; it was easy then to eliminate it.

The early phases of this study were done using the transverse vibration loosening machine developed earlier. Then after the fixturing routine was developed the actual tests were done on an MTS fatigue testing machine.

A US patent was obtained as a result of this work

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Self-loosening test rig installed on a hydropulsator

MAHLE Industries Inc, Farmington Hills, MI Copyright © 2010 SAE International

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