SiSmaK - Sensor-integrated bolts for multiaxial force measurement and derivation of a design methodology for sensor integration in closed cylindrical machine elements

点击翻译按钮获取中文摘要

Key elements for the broad use of Industry 4.0 are measurement and process data with high data quality. This can be achieved by sensors on site, i.e., at the process-relevant locations in the machine. Fasteners such as bolt connections are particularly suitable for this, as they are in the flow of forces. Besides they are among the most common component connections. The load on a bolt connection usually is multi-axial. For example, transverse forces already affect the bolt during conventional assembly due to the torsional load. Further, during operation, there are bending and shear stresses in the head area, which act on the bolt in addition to the axial pre-tensioning force. However, in the systematic calculation of highly stressed bolt connections according to VDI 2230, this is reduced to a mono-axial load by using strength hypotheses and correction factors. But the multi-axial force measurement is indispensable, in particular for the acquisition of loads from different directions and their use for process monitoring with early fault detection.To meet the interdisciplinary challenges in the development of sensor-integrated machine elements, special methodologies are necessary. In the state of research, such methodologies are lacking for the design of sensor-integrated machine elements. Therefore, in this project a design methodology for cylindrical machine elements is investigated, which addresses the aspects of sensor integration, energy management and signal transmission.Thus, the aim of this project is designing and solving the interdisciplinary research questions of a sensor-integrating bolt with multi-axial force measurement, which meets the requirements of seamless integration, a self-sustaining energy supply and hermetic sealing. At the same time, the primary function of load-bearing capacity should be affected as little as possible. The procedure for realizing this goal also will be used to extend existing design methodologies for mechatronic systems, in particular for the development of sensor-integrated machine elements. For this purpose, a methodology for cylindrical machine elements is to be abstracted based on established design methodologies and from the approach used in this research project. This methodology represents a high degree of coherence with the objectives of the priority program and extends the state of research on design methodologies for sensor-integrated machine elements.To achieve this goal, several test carriers with different complexity and maturity are realized based on a conventional metric bolt and are evaluated on a test setup which will be developed simultaneously. For the development of the design methodology, all steps taken are continuously reflected and the findings are transferred into a design methodology for closed, cylindrical machine elements.