smartCAST – digital castings with condition monitoring for autonomous vehicles

smartCAST â 具有自动驾驶车辆状态监测功能的数字铸件

• 批准号: 440971991
• 负责人: Professor Dr.-Ing. Walter Lang
• 金额: --
• 依托单位: Bereich Formgebung und Funktionswerkstoffe
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/440971991?language=en
• 关键词: smartCAST; digital; castings; condition; monitoring

Two technological developments are currently changing the global automotive industry: the electric drive and autonomous driving. The autonomous vehicle faces new challenges in terms of vehicle safety. Until now, the main topic has been the active monitoring of road conditions, weather conditions, or e.g. children playing on the road. However, one aspect has been strongly neglected or not considered at all: the passive safety of the vehicle. For this purpose, proven and well-known technology of current vehicles has been used so far. Safety-relevant components of the vehicle were dimensioned with generous safety factors. And if damage to the vehicle has occurred in the past - whether actively caused by the driver, due to unintentional driving maneuvers or passively due to external influences - the driver has usually felt this in the steering wheel. However, by "letting go" of the steering wheel when driving autonomously, the driver separates himself from the "tactile" state of his car.The chassis in particular is considered a safety-relevant vehicle structure and influences the driving dynamics and the control of hazards in an emergency. Until now, this has been perceived solely by the driver, but with the elimination of the steering wheel in level 5 of autonomous driving, this task will in future be left entirely to the vehicle itself. An increase in drama follows from the inexorably increasing trend towards car sharing and the associated decline in the sense of responsibility towards the vehicle. Any damage caused - and the associated safety risk - is passed on directly to the next user. Future car-sharing operators in particular recognise the necessity of checking the safety-relevant components (e.g. chassis) for critical damage in a quick check, at least when the vehicle is started up again.The aim of the transfer project is to enable the safety-relevant components in the autonomous vehicle to have such a "body feeling" by means of embedded sensors. These components are usually made of cast aluminium. Within the framework of the DFG-funded project "SINA", the applicants have developed the first principles for the direct casting of load sensors based on thick-film technology in aluminium casting. The encapsulated sensors enable the detection, measurement and assessment of mechanical loads. They provide early warning of overloading, damage and failure of the components. Thanks to the piezoresistive sensor principle, data can be recorded both during the operating phase in real time and during commissioning. This means that an inspection for deformation or damage to the casting can be carried out at any time. In the transfer project, these basic findings are to be applied to concrete scenarios and castings for autonomous vehicles and completed for a later series application together with research and industry partners.

目前，两项技术发展正在改变全球汽车行业：电动驱动和自动驾驶。自动驾驶汽车在车辆安全方面面临新的挑战。到目前为止，主要的主题是主动监测道路状况、天气状况或例如在路上玩耍的儿童。然而，有一个方面被严重忽视或根本没有考虑：车辆的被动安全性。为此目的，迄今为止已经使用了当前车辆的成熟和众所周知的技术。车辆的安全相关部件的尺寸具有慷慨的安全系数。 如果车辆在过去发生过损坏-无论是由驾驶员主动造成的，由于无意的驾驶操作或被动地由于外部影响-驾驶员通常会在方向盘上感受到这一点。然而，当自动驾驶时，驾驶员通过“放开”方向盘，将自己从汽车的“触觉”状态中分离出来。特别是底盘被认为是与安全相关的车辆结构，影响驾驶动力学和紧急情况下的危险控制。到目前为止，这只被驾驶员感知到，但随着第5级自动驾驶中方向盘的消除，这项任务将完全留给车辆本身。戏剧性的增加是由于汽车共享的不可阻挡的增长趋势以及对车辆的责任感的相关下降。造成的任何损害-以及相关的安全风险-都将直接传递给下一个用户。未来的汽车共享运营商尤其认识到，至少在车辆再次启动时，需要快速检查安全相关部件（例如底盘）是否存在严重损坏。转移项目的目的是通过嵌入式传感器使自动驾驶车辆中的安全相关部件具有这种“体感”。这些部件通常由铸铝制成。在DFG资助的项目“SINA”的框架内，申请人已经开发了基于铝铸造中的厚膜技术的直接铸造载荷传感器的第一原理。封装的传感器能够检测、测量和评估机械负载。它们提供过载、损坏和部件故障的早期预警。由于压阻式传感器的原理，可以在运行阶段以真实的时间和调试期间记录数据。这意味着可以随时检查铸件的变形或损坏。在转移项目中，这些基本发现将应用于自动驾驶汽车的具体场景和铸件，并与研究和行业合作伙伴一起完成后续系列应用。