Project Details
Projekt
Load sensitive spline shaft with sensory material
Subject Area
Engineering Design, Machine Elements, Product Development
Term
since 2021
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 466760574
The aim of the project is to integrate an autonomous sensor system into the splined shaft machine element while maintaining the primary function of the system. Splined shaft connections are among the most heavily loaded machine elements in the drive train and are usually located in the centre of the power flow. A material sensor is used in conjunction with an eddy current testing system as an evaluation unit to detect mechanical overloads on the splined shaft. The principle of the material sensor is based on a permanent structural transformation of paramagnetic austenite into ferromagnetic martensite. The proportion of martensite formed under cyclic load depends on the load amplitude and the number of load cycles. The structural transformation occurs in the material sensor at load amplitudes well below the yield point. A higher load always produces martensite, which means that the material sensor is not consumed after the load is exceeded. The magnetic changes can be detected using electromagnetic testing technology. The realisation of load detection and information storage by the sensor material, which performs this function without an external energy supply and enables readout at long intervals, leads to particularly energy-efficient component monitoring. In the first funding period, proof of function was provided for all necessary modules for an autonomous, load-sensitive splined shaft that detects overloads and transmits eddy current test data wirelessly. In the second funding period, a robust and energy-efficient sensor-integrated machine element (SiME) will be developed based on the results of the first funding period, which guarantees the autonomy of the energy supply and data transmission. Another objective is to ensure that the MCU software and the evaluation algorithm can be updated. A further focus is on ensuring the component and functional reliability of the individual basic functions of the overall system. The long-term stability of the sensor functions is also of decisive importance for the overall performance of the system over the service life of the splined shaft. In addition, a comprehensive framework for the design and simulation of the SiME is being developed to complement existing standards in a suitable form.
DFG Programme
Priority Programmes
