Sensor Fastener With Energy Harvesting for Predictive Maintenance
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Solution Overview
Problem
Conventional fasteners with sensors are bulky, heavy, and limited to static torque detection during tightening, lacking the ability to dynamically monitor working conditions and predict maintenance needs in mechanical apparatuses, leading to inefficient maintenance scheduling and potential breakages.
Innovation Solution
A fastener with integrated sensors and an energy harvesting system, capable of wirelessly communicating with a control system to remotely monitor mechanical apparatuses, detecting vibrations, thermal stresses, and other parameters, and performing predictive maintenance without the need for wired connections or batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional adaptors with sensors are used to detect tightening torque, then torque detection is enabled, but the adaptor becomes bulky and heavy
Solution Approach 1:
The patent combines the sensor system, power supply (battery), and wireless communication module into an integrated fastener component that is directly installed on the fastener. This merging eliminates the need for a separate bulky adaptor while maintaining torque detection capability through strain gauges and other sensors mounted directly on the fastener body.
Solution Approach 2:
The patent replaces the mechanical adaptor structure with a miniaturized electronic system that uses strain gauges, piezoelectric sensors, or capacitive sensors to detect torque. This substitution allows for significantly reduced size and weight while maintaining measurement precision through electronic sensing rather than mechanical leverage.
2Loss of information
If sensors are installed in fasteners for dynamic monitoring, then real-time working condition detection is enabled, but the fastener structure becomes more complex
Solution Approach 1:
The fastener is designed to perform multiple functions: mechanical fastening, torque detection through strain gauges, acceleration monitoring via accelerometers, temperature sensing with thermocouples, and wireless data transmission. This multi-functionality consolidates what would otherwise require separate components into a single integrated unit, reducing overall system complexity.
Solution Approach 2:
The patent nests multiple sensor systems and electronic components within the existing fastener geometry. The battery, circuit board, and sensors are integrated into the fastener head or shaft, with components arranged concentrically or in layered configurations that utilize the fastener's internal volume efficiently, minimizing external dimensional increases.
3Reliability
If wired connections are used for sensor data transmission, then reliable data transfer is achieved, but the system loses remote monitoring capability
Solution Approach 1:
The patent replaces physical wired connections with wireless communication technology (such as RFID, Bluetooth, or Wi-Fi modules) to transmit sensor data from the fastener to external monitoring systems. This substitution maintains data transmission reliability through error correction protocols while enabling remote monitoring without physical contact or cable connections.
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
Enables continuous, remote monitoring and predictive maintenance, reducing maintenance frequency and costs by detecting actual working conditions in real-time, enhancing the reliability and efficiency of mechanical apparatus operations.
Implementation Method 1
an energy harvesting system, configured to transform one or more sources of energy into electricity
Implementation Method 2
an energy harvesting system, configured to transform one or more sources of energy into electricity
Implementation Method 3
the function of dynamically generating signals (in particular electromagnetic signals) based on the working conditions, namely the instantaneous use conditions of the fastener in combination with any physical phenomena that instantaneously cross the fastener
Data Source
AI summary
A monitoring method by means of a monitoring system having a first terminal device and a second terminal device is provided. The first terminal device is a control system and the second terminal device is a fastener, e.g., a screw, which fixes together, in use, two or more components of a mechanical apparatus. The second terminal device is provided with one or more sensors and a printed circuit board with a wireless communication portion. The first terminal device and the second terminal device exchange data wirelessly directly and/or indirectly, e.g., via a transport network, such as a telecommunications network.