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

工业4.0广泛应用的关键要素是高数据质量的测量和过程数据。这可以通过现场的传感器来实现，即，在机器中与工艺相关的位置。螺栓连接等紧固件特别适合于此，因为它们处于力的流动中。此外，它们是最常见的组件连接。螺栓连接上的载荷通常是多轴的。例如，由于扭转载荷，横向力在传统组装期间已经影响螺栓。此外，在操作期间，在头部区域中存在弯曲应力和剪切应力，其除了轴向预紧力之外还作用在螺栓上。然而，在根据ASTM 2230的高应力螺栓连接的系统计算中，通过使用强度假设和校正系数，这被简化为单轴载荷。但是，多轴向力测量是必不可少的，特别是从不同方向获取载荷，并将其用于过程监控和早期故障检测。为了应对传感器集成机器元件开发中的跨学科挑战，需要特殊的方法。在研究的状态，这样的方法是缺乏的传感器集成的机器元件的设计。因此，本项目研究了圆柱形机械元件的设计方法，涉及传感器集成、能量管理和信号传输等方面，因此，本项目的目的是设计和解决具有多轴向力测量的传感器集成螺栓的跨学科研究问题，该螺栓满足无缝集成、自维持能量供应和密封的要求。同时，承载能力的主要功能应尽可能少地受到影响。实现这一目标的过程也将用于扩展现有的机电系统设计方法，特别是传感器集成机器元件的开发。为此，圆柱形机器元件的方法是抽象的基础上建立的设计方法，并从本研究项目中使用的方法。该方法与优先计划的目标高度一致，并扩展了传感器集成机器元件设计方法的研究状态。为了实现这一目标，基于传统的公制螺栓实现了几种不同复杂性和成熟度的测试载体，并在同时开发的测试装置上进行评估。对于设计方法的开发，所采取的所有步骤都被不断地反映出来，并将结果转化为封闭的圆柱形机器元件的设计方法。

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.