Machine tool manufacturer Company “Y”

Realizes maintenance-free predictive equipment failure detection sensorNo power supply for sensors to be installed optimal location...


In the Japanese manufacturing industry, it is becoming difficult to secure field workers due to labor shortages. Therefore, the introduction of a predictive maintenance system that digitizes equipment noise and vibration with sensors which detects deterioration of machinery and equipment in advance is progressing. In addition, in order to avoid increased repair costs and opportunity loss due to equipment failure, there is a growing need for failure sign monitoring systems utilizing IoT that can be retrofitted to existing equipment and do not require remodeling. Machine tool manufacturer “Y” provides a fault sign monitoring system that can be attached to equipment, but they faced issue where those sensors can be installed.


The sensing device cannot be placed at the best location to detect abnormal vibrations of an equipment

Sensors that detect noise, vibration, etc. also need a power source to communicate those information. Since it is difficult to secure power supplies with wired sensors that are attached to existing equipment, wireless sensors with built-in power supplies are often used. Because robotic arms have many complex movements like human arms, parts can deteriorate and wear out quickly, and small sensor devices were required to detect abnormalities of equipment. However, the tip of the robot arm is thin, and the dimensions are too large for devices using primary (non-rechargeable) batteries, and it is not possible to be placed in an area where it can detect vibrations with accuracy. There was also the problem that batteries needed to be replaced regularly, which was very time consuming.

Need a rechargeable battery that can be used even at high temperature

In addition, there was a problem that wireless sensors could not be installed in high-temperature processing rooms. With ultra-high-speed rotating equipment and high-speed machining centers, the temperature in the processing room rises due to heat generation and processing heat from the motor. The conventional rechargeable batteries with low heat resistance cannot be used. When trying to take the power supply of the vibration sensor from the system’s original power supply, the wiring is disturbing and it is difficult to install it at the end of the equipment. Customers have requested the system configuration to be more simple and compact.

Main Issues

  • Primary (non-rechargeable) batteries have larger device dimensions, cannot be installed at the end of the machine, and is required to replace batteries frequently.

  • Ultra-high-speed rotating devices and high-speed machining centers require rechargeable batteries that can withstand high temperatures.

  • In some cases, a wide range of operating temperatures are required from low to high, which is difficult to respond with conventional rechargeable batteries.