Embedded Cast Component Sensor for Mechanical Load Detection
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Solution Overview
Problem
Current methods for detecting mechanical loads and deformations in cast components are complex, costly, and not robust, leading to potential component failure due to overloading, which contradicts the goal of lightweight construction in vehicle technology and increases the risk of damage in safety-relevant components.
Innovation Solution
A device with a cast component embedded sensor, designed as a short-circuit element or light guide, which interrupts or establishes an electrical or light connection upon mechanical load or deformation, emitting a signal to indicate the load or deformation, allowing for early detection and prevention of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cast components are designed with over-dimensioning to withstand heavy loads, then component strength and reliability are improved, but component weight increases unnecessarily
Solution Approach 1:
Sensors are embedded in the cast component during the casting process itself, before the component is put into service. This preliminary integration allows for continuous monitoring of mechanical stresses and deformations, enabling the component to be designed with optimal rather than excessive dimensions, thereby reducing weight while maintaining reliability.
Solution Approach 2:
The sensor system provides real-time feedback on mechanical stresses and deformations in the cast component. This feedback enables monitoring of actual load conditions, allowing the component to be designed with precise dimensions based on actual usage patterns rather than conservative over-dimensioning, thus reducing unnecessary weight while maintaining strength.
2Reliability
If sensors are integrated into cast components to detect mechanical loads, then detection capability and safety are improved, but device complexity increases
Solution Approach 1:
Sensors are embedded in the cast component during the casting process itself, before the component is put into service. This preliminary integration allows for continuous monitoring of mechanical stresses and deformations, enabling the component to be designed with optimal rather than excessive dimensions, thereby reducing weight while maintaining reliability.
Solution Approach 2:
The sensor system is designed to be self-contained and integrated within the cast component structure. The sensors monitor their own environment and provide automatic signals when threshold values are exceeded, eliminating the need for complex external monitoring systems and reducing overall device complexity.
3Measurement precision
If traditional sensors are used for detecting mechanical stresses, then measurement precision is improved, but manufacturing cost and robustness worsen
Solution Approach 1:
The sensor embedding process is merged with the casting process itself. Sensors are placed in molds or inserts that are integrated into the casting setup, allowing sensors to be embedded automatically during normal production without requiring separate, costly post-processing steps. This merging of processes reduces manufacturing cost while maintaining measurement precision.
Solution Approach 2:
Sensors are embedded in the cast component during the casting process itself, before the component is put into service. This preliminary integration allows for continuous monitoring of mechanical stresses and deformations, enabling the component to be designed with optimal rather than excessive dimensions, thereby reducing weight while maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables simple, cost-effective, and robust detection of mechanical loads and deformations, reducing the need for structural oversizing and preventing damage to cast components, thus enhancing safety and reducing material weight.
Implementation Method 1
The at least one sensor is designed in the form of at least one short-circuiting element or in the form of at least one optical fiber... upon a specific mechanical stress and/or deformation of the cast component, an electrical connection or an optical path in the at least one sensor is interrupted or established
Implementation Method 2
The short-circuiting element comprises at least one electrically conductive component and at least one electrically insulating component... upon a specific mechanical stress and/or deformation of the cast component, an electrical connection or an optical path in the at least one sensor is interrupted or established
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a cast component comprising a cast base body and at least one sensor at least partly embedded in the cast base body for detecting mechanical loads and/or deformations of the cast component. The at least one sensor is designed in the form of at least one short-circuit element or in the form of at least one optical conductor. The short-circuit element comprises at least one electrically conductive component and at least one electrically insulating component, which insulates the at least one electrically conductive component electrically with respect to the cast base body. According to the invention, the at least one sensor is designed and arranged such that, beginning at a specific mechanical load and/or deformation of the cast component, an electrical connection or a light conductor in the at least one sensor is interrupted or produced. The invention further relates to a method for producing the cast component according to the invention, to a device comprising the cast component according to the invention for detecting mechanical loads and/or deformations in the cast component, and to the use of the cast component according to the invention and of the device according to the invention.