Sensor-integrating feather keys for the detection of torques

滑键联接（PFV）是固定传动技术领域中广泛使用的轴毂联接（WNV）。键齿（PF）在轴和毂之间形成形状配合，使得负载（通常为扭矩）可以在轴和毂之间传递。由于传动系中的运行载荷通常通过WNV引入和移除，PF特别适合现场测量。因此，整个项目的首要目标是对滑键进行基于传感器的升级，以便通过传递的周向力记录通过变形施加到WNV上的扭矩。传感器信号将在机器元件中直接处理并无线传输。通过能量收集，在机器元件中直接产生所需的能量。这里的一个挑战是通过合理的感官努力检测沿着滑键长度的非均匀、轮毂和扭矩相关的表面压力的合力。这是本项目工作假设的起点，即PF的刚度可以通过以下方式进行调节，即其变形减少到具有良好近似的少量模态自由度，因此，仅使用几个应变传感器就可以记录PF上的荷载。在本项目范围内，应开发一种总体方法，其允许通过相互作用的单独方法设计、确定尺寸和/或定位传感器集成滑键的不同模块（PF的刚度调节体、具有相应信号转换器的应变传感器、由能量转换器以及能量存储和管理系统组成的能量收集系统、微控制器和无线发射器）。此外，还将开发相应的评估算法和传输策略。在PFV实验和数值研究的帮助下，将对各个方法进行验证，并对各个模块进行表征。此外，还将确定评估模块和传输单元的能耗。在第一个资助期内，传感器集成PF的认证将在模块一级进行。计划在战略规划方案的第二个供资期内将各个单元直接完全纳入方案框架。这也包括更复杂的载荷情况以及干扰影响的考虑。迄今为止还没有系统地利用模态刚度调节来最大限度地减少感官效果，并且与PF的纯感官增强研究相比，这代表了一个实质性的进步。会很简单

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.