Load sensitive spline shaft with sensory material

资源高效机器的开发和运行在很大程度上取决于实际负载的高质量信息的可用性。直接从现场关键部位获得的信息是最有价值的。这需要机器的全面数字化，这本身就依赖于廉价和现成的测量系统。发展这种系统的一个主要挑战是能源自给自足；像应变计这样的传统系统需要在高频下进行恒定的电力测量操作。在优先项目2305“传感器集成机器元件”（SiME）的背景下，研究了花键轴上的材料集成，感觉外围区域条件作为满足所述要求的可能解决方案，与最先进的技术相比，其功率需求大大降低。传感器材料的原理是基于当应力超过极限载荷时，从亚稳奥氏体到马氏体的结构转变。通过涡流分析可以检测到结构的变化。传感材料存储负载信息，不需要电源，可以在任意间隔读取。感应材料外围区可通过激光热处理局部定制。研究计划应确定通过材料传感器开发可重复SiME的可能性，这些传感器的特点是低功耗要求、高质量的信息、对机器元件主要功能的影响可忽略不计。重点在于结构设计的方法学研究，传感器对机器元件的影响分析，以及传感器材料的认证。通过在试验台的轴-轮毂连接样品上使用该项目开发的能量收集驱动的节能原型涡流读取器进行验证。最后，考虑了有关进一步度量的可更新性和可扩展性。

The development and operation of highly resource-efficient machines greatly depends on the availability of high-quality information on the actual loads. Information gained directly from the critical parts in the field is the most valuable. This requires comprehensive digitization of machines, which in itself depends on inexpensive and readily available measuring systems. A major challenge in the development of such systems is energy self-sufficiency; conventional systems like strain gauges require a constant electrically powered measurement operation at high frequency. In the context of priority program 2305 "Sensor-integrating machine elements" (SiME), a material-integrated, sensory peripheral zone condition on a splined shaft as a possible solution satisfying the stated requirements featuring drastically lowered power demand compared to state of the art technology is researched. The principle of the sensor material is based on a structural transformation from metastable austenite to martensite when stressed above a limit load. The structural transformation can be detected via eddy-current analysis. The sensory material stores the load information, requires no electric power supply and can be read at arbitrary intervals.. The sensory material peripheral zone can tailored locally by laser heat treatment. The research program shall establish the possibility of developing reproducible SiME via material sensors characterized by low power requirements, high quality of information, and negligible impact on the main function of the machine element. Focus lies on the methodological study of structural design for incorporation, the analysis of the sensors impact on the machine element, and the certification of the sensor material. Verification is achieved using an energy efficient prototype eddy current reader unit powered by energy harvesting developed in the project on shaft-hub connection specimens in a test rig. Finally, the updateability and the expandability concerning further measurands is considered.