Sensor Washer Structure to Prevent Shear Damage in Screw Joints
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Solution Overview
Problem
Existing screw connection systems with sensor layers face damage during fastening due to shearing movements, compromising their durability and ergonomics.
Innovation Solution
A washer with a carrier element and counter element, featuring a sensory layer system between them, which limits rotation and prevents damage by engaging through a form-fit geometry, allowing for the monitoring of forces and vibrations while protecting the sensor layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor disk or sensor layer is used to measure force in the screw connection, then force monitoring capability is improved, but the sensor is damaged due to shearing movements during fastening
Solution Approach 1:
The washer is divided into a carrier element and a counter element that can move relative to each other along the screw axis. The sensor layer is placed between these two elements, allowing the counter element to move independently to absorb shearing movements during fastening, thereby protecting the sensor from damage while maintaining force monitoring capability.
Solution Approach 2:
The counter element acts as an intermediary between the sensor layer and the external fastening forces. It absorbs the shearing movements and mechanical stresses during tightening, preventing direct transmission of damaging forces to the sensor layer while allowing the sensor to continue measuring the axial force.
2Reliability
If the carrier element and counter element are allowed to move relative to each other to protect the sensor, then sensor protection is improved, but rotational stability is worsened
Solution Approach 1:
The washer has different degrees of freedom in different directions: along the screw axis, the carrier element and counter element can move relative to each other to protect the sensor, but in the radial direction, they are constrained by the form-fit geometry (tooth-to-groove engagement) to prevent rotation and maintain stability.
Solution Approach 2:
The washer design allows dynamic movement of the counter element relative to the carrier element along the screw axis during fastening to absorb shearing forces, while the form-fit geometry dynamically prevents rotational movement, creating a controlled dynamic system that adapts to fastening forces.
Data Source
AI summary
Washer, including: a carrier element; a counter element; and a sensory layer system arranged between the carrier element and the counter element and configured to output a sensor signal on the basis of a force prevailing between the carrier element and the counter element along a screw axis and/or a prevailing pressure force or vibration; wherein the carrier element and the counter element are arranged along a screw axis and wherein the carrier element includes a geometry that is engageable with a geometry of the counter element so as to limit or prevent a rotation between the carrier element and the counter element.