Design and verification of a wireless readout system for integrated motor axle condition monitoring

Online condition monitoring of motors has the potential to significantly reduce costs related to maintenance, improve operational safety and increase lifetime of the systems. Machine integrated sensor systems, with wireless readout can enable seamless deployment of such monitoring systems. This paper presents a system developed for the online monitoring of a critical point of wear in rotating machines; the axle-bearing interface in a motor. An acceleration sensor is integrated into a 3D printed motor axle along with its wiring to provide an interface on the axle end. A readout system with wireless communications is developed. Spin testing of the device is carried out on a test motor and simple verification of the integrated sensor presented.