Current projects


Validation Infrastructure for Condition Monitoring of large Gearboxes in Industrial Applications


Condition monitoring of machines and plants in operation for high productivity and simultaneous energy efficiency is one of the major goals of Industry 4.0, which is generally attempted to be achieved by increasing the quantity of measurement data. However, by obtaining less, but high-quality data directly in the mechanically stressed drive (in-situ), additional knowledge can be generated. Such systems must first be validated at full scale. The necessary validation infrastructure is currently not available.

Project goals

The aim of the project is to validate the research approaches regarding condition monitoring of industrial plants by means of sensing machine elements that enable in-situ measurement of relevant process variables. The focus is on clarifying the potential and advantages of the novel technology in comparison to established approaches. The application-oriented validation lays the foundation for the transfer to industry and diffusion of the technology.

To create the necessary validation infrastructure, a drive element test bench of 350 kW including the necessary measurement technology and other components for simulating realistic environmental conditions is to be procured in order to create a validation environment that is as close to the application as possible.

Planned structure and procedure

The overall project will be carried out from 01.02.2019 to 30.09.2022. First of all, the planned, illustrated test setup will be specified, procured and put into operation. The test setup consists of two electrical machines including converters and measurement technology, which are set up in a back-to-back arrangement. This means that one electrical machine acts as a drive and the other as a brake, thus realising an electrical bracing with minimal losses. After commissioning, initial validation studies can be carried out with cooperation partners. Sensor technology developed by the department will also be researched on the test bench. For example, tests are planned using a gear wheel as a measuring scale to measure the instantaneous angular speed. The recorded data will finally be combined in a digital twin and evaluated in a targeted manner.

Figure 1: Schematic diagram of the test setup

Cooperation opportunities

The expansion of the validation infrastructure should also offer companies the opportunity to validate their research and development approaches in the field of condition monitoring. Therefore, there are a number of opportunities for cooperation. If you and your company are interested in using the validation infrastructure, simply contact us.


This project is half funded by the European Union within the framework of the European Regional Development Fund (ERDF). Funding is provided for the establishment and operation of competence and application centers at universities and research institutions.