Sensor-Integrated Connection Element for Load Monitoring
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Solution Overview
Problem
Existing connection elements in vehicle and machinery construction lack efficient and cost-effective means to monitor axial and transverse loads continuously, with existing solutions being complex, costly, and prone to false readings due to additional resilience and complexity introduced by external sensors.
Innovation Solution
A support structure with integrated sensor technology that combines a longitudinally oriented threaded region and a resilient region, where the sensor unit is coaxially arranged inside, allowing for continuous monitoring of axial and transverse loads, and extended by temperature and humidity sensors to compensate for interference, with a manufacturing method that integrates the sensor unit during shaping to ensure force transmission and maintain pretensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are added to monitor loads, then measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The sensor unit is integrated directly into the connection element itself, merging the monitoring function with the structural component. This eliminates the need for separate external sensors and their associated mounting hardware, thereby reducing device complexity while maintaining load monitoring capability.
Solution Approach 2:
The connection element serves dual purposes: it provides mechanical fastening functionality and simultaneously acts as a sensor carrier for monitoring loads. This multi-functionality reduces the overall system complexity by eliminating dedicated external monitoring devices.
2Measurement precision
If external sensors are added to monitor loads, then measurement capability is improved, but manufacturing cost increases
Solution Approach 1:
By integrating the sensor unit into the connection element during the same manufacturing process, the patent eliminates separate assembly steps and reduces overall manufacturing cost. The sensor-containing connection element is produced as a single integrated component rather than assembling multiple separate parts.
Solution Approach 2:
The sensor unit is pre-integrated into the connection element during manufacturing, before installation. This preliminary integration simplifies the overall manufacturing process and reduces costs by eliminating field installation of external sensors and associated labor.
3Measurement precision
If additional elements are built into the connection, then measurement capability is improved, but additional resilience and production tolerance issues arise
Solution Approach 1:
The sensor unit and connection element form an integrated assembly with predetermined geometric relationships. This integration eliminates the need for separate mounting of external sensors, thereby avoiding the resilience and tolerance accumulation problems that arise from multiple separate components being assembled together.
Data Source
AI summary
A connection element consists of a longitudinally oriented support structure that is at least partially hollow and a sensor unit that is arranged in the inside of the support structure, is connected to a signal transmission device, and is non-positively connected to the support structure. The required force for the non-positive connection is produced by internal stresses after a plastic deformation of the support structure during a joining process of the support structure and the sensor unit. A method for manufacturing a connection element consisting of a support structure that is at least partially hollow and a sensor unit includes positioning the sensor unit in a region of the support structure and, using radially movable tool segments, exerting a force on the support structure in the radial direction and at the same time reducing the periphery of the support structure in the region in which the sensor unit is positioned.