Sensor-integrating feather keys for the detection of torques

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The feather-key connection (PFV) is a widely used shaft-hub connection (WNV) in the field of stationary drive technology. The key feather (PF) creates the form fit between the shaft and hub so that loads, typically torques, can be transmitted between the shaft and hub. Since the operating loads in drive trains are usually introduced and removed via WNV, the PF is particularly suitable for in-situ measurements.The overriding objective of the overall project is therefore the sensor-based upgrading of feather keys in order to record the torques applied to the WNV via their deformation by means of the transmitted circumferential force. The sensor signals are to be processed directly in the machine element and transmitted wirelessly. The energy required for this is generated directly in the machine element by means of energy harvesting.One challenge here is the detection of the resulting force of the non-uniform, hub- and torque-dependent surface pressure along the feather-key length with justifiable sensory effort. This is the starting point of the working hypothesis of the project, which states that the stiffness of the PF can be conditioned in such a way that its deformation is reduced to a small number of modal degrees of freedom with good approximation, and thus the load running over the PF can be recorded with only a few strain sensors.Within the scope of the project, an overall methodology shall be developed, which allows the design, dimensioning and/or positioning of the different modules (stiffness-conditioned body of the PF, strain sensors with corresponding signal converter, energy harvesting system consisting of energy converter as well as energy storage and management system, microcontroller and wireless transmitter) of the sensor-integrating feather-key via mutually interacting individual methods. In addition, a corresponding evaluation algorithm and a transmission strategy are to be developed.With the help of experimental and numerical investigations at the PFV, the individual methods are to be validated and the respective modules characterized. In addition, the energy consumption of the evaluation module and the transmitting unit will be determined.In the first funding period, the qualification of the sensor-integrating PF will take place at the module level. A complete integration of the individual modules directly in the PF is planned in for the second funding period of the SPP. This also includes the consideration of more complex load cases as well as disturbance influences.A systematic exploitation of the modal stiffness conditioning to minimize the sensory effort has not been done so far and represents a substantial progress compared to the state of the art in research besides the pure sensory enhancement of the PF. Adaptation of the overall development methodology to alternative WNV, such as taper clamping sets, would be straightforward.