Sensorial shaft - in-situ measurement of process-relevant state variables in frictional connections

随着技术的不断进步和数字化的发展，传统机械元件（ME）正成为智能附加功能和数字网络开发的重点。作为其中的一部分，传感器集成机器元件旨在实现现有驱动技术系统的数字化，而无需进行昂贵的新研究。进一步开发和集成额外的测量功能，直接在ME中记录物理变量，这是一种很有前途的方法。这种传感器集成在产品开发和现场状态监测中提供了相当大的附加值。车轴和轴是传动系统中传递力和力矩的核心部件。轴毂连接（SHC）对于实现其主要功能至关重要。在这种应用中，可拆卸接合连接（压力和夹紧连接、夹紧装置等）经常使用的变种。迄今为止，设计SHC的相关变量（摩擦力或法向力）无法直接测量，而是由其他变量间接确定。这不可避免地导致设计中的高偏差和不确定性。在操作中需要有意义的状态变量，这使得直接在组件上确定各种变量变得至关重要。为此，速度和振动传感器将由薄膜传感器系统补充，该系统能够现场测量部件上的机械应力、应变和温度。作为中央驱动技术元件的ME轴特别适合于承载传感器系统，以确定广泛和可靠的操作数据。现有的设计规范可以确保未来在轴中集成传感器的标准化方法，而不会显著影响主要功能。基于多功能薄膜系统的传感器首次实现了对直接部件接触的局部特性和过程参数（例如法向应力和剪应力以及温度）的精确的空间和时间分辨确定。

With increasing technical advances and the resulting digitalization, classic machine elements (ME) are becoming a focus for the development of smart additional functions and digital networks. As part of that, sensor-integrated machine elements are intended to enable the digitalization of existing drive technology systems without expensive new investigations. The further development and integration of additional measurement functions for recording physical variables directly in the ME represents a promising approach here. Such a sensor integration offers considerable added value in product development and in condition monitoring in the field. Axles and shafts are the central ME for the transmission of forces and moments in drive systems. Shaft-hub connections (SHC) are essential for fulfilling their primary function. In this application frictionally engaged connections (press and clamp connections, clamping sets, etc.) being frequently used variants. The relevant variables (friction or normal force) for designing SHCs up to now, cannot be measured directly, but is determined indirectly from other variables. This inevitably leads to high deviations and uncertainties in the design. The need for meaningful state variables in operation makes it essential to determine various variables directly on the component. For this purpose, speed and vibration sensors are to be supplemented by a thin-film sensor system that enables in-situ-measurement of mechanical stresses, strains and temperatures on the component. The ME shaft as a central drive technology element is particularly suitable to carry the sensor system for the determination of extensive and reliable operating data. Existing design specifications can ensure a future standardized method for sensor integration in shafts without significantly affecting the primary function. Sensors based on multifunctional thin-film systems enable for the first time a precise spatially and temporally resolved determination of local characteristics and process parameters in direct component contact such as normal and shear stresses as well as temperature.