Project Details
Projekt
SiSmaK 2 - Sensor-integrated bolts for multiaxial force measurement and derivation of a design methodology for sensor integration in closed cylindrical machine elements
Applicants
Professor Dr.-Ing. Klaus Hofmann; Professor Dr. Mario Kupnik; Professor Dr.-Ing. Sven Matthiesen
Subject Area
Engineering Design, Machine Elements, Product Development
Electronic Semiconductors, Components and Circuits, Integrated Systems, Sensor Technology, Theoretical Electrical Engineering
Measurement Systems
Electronic Semiconductors, Components and Circuits, Integrated Systems, Sensor Technology, Theoretical Electrical Engineering
Measurement Systems
Term
since 2025
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 551302077
Standardized machine elements are ideal measuring locations for the comprehensive acquisition of meaningful process data. As a widely used fastener, bolts in particular are suitable for recording loads in machines, as they are located directly in the force flow. Within the framework of the DFG priority program 2305, a bolt with integrated, multi-axial force measurement is being developed in the SiSmaK sub-project. Full integration of the electronics is planned for autonomous operation. A methodology for sensor integration in cylindrical machine elements is being derived. Initially, the functional reliability of the sensor-integrating bolt for multi-axial force measurement is to be verified over its entire service life. This includes the development of a method for calibrating multiaxial force sensors with large working ranges, as well as the reliability assessment of the overall mechatronic system. For the evaluation, relevant environmental conditions and general requirements should first be identified and mapped in standardizable tests. In addition to maintaining the mechanical interfaces, robustness in field use must also be guaranteed. To this end, the bolt is to be completely encapsulated. Electromagnetic and acoustic principles are to be used for energy and data transmission and methods for transmitting energy and data through steel are to be researched, which can be transferred to encapsulated electronics and enable autonomous operation of the sensor system. With known real-time data on the load condition, bolted joints can be optimized already in the assembly stage. The disadvantages of conventional torque-controlled tightening methods can be overcome by reducing the uncertainty of the preload force achieved and the associated oversizing. In the project, this potential is exploited by a novel information technology coupling between the sensor-integrating bolt and an assembly tool. As part of the priority program, the networking of diverse sensor-integrating machine elements in an IIoT structure is being investigated. The collaboratively developed protocols and interfaces are to be integrated into a gateway for the newly developed data transmission technology as part of the project. The design methodology developed in the research project can also be transferred to the mechatronic problems of other cylindrical machine elements. This includes identifying the design space, designing the sensor, integrating the electronics and transmitting energy and data through steel.
DFG Programme
Priority Programmes
