Design and development of a load-sensitive autonomous splined shaft with material sensors, integrated evaluation unit, wireless data transmission and energy harvesting

This article summarises the main research findings of the first funding period of the project “Load sensitive spline shaft with sensory material”, which is part of the DFG Priority Programme 2305 “Sensor-Integrated Machine Elements Pave the Way for Widespread Digitalization”. In the present project, the combination of a load-sensitive material sensor and eddy current testing is used for load monitoring. The splined shaft was designed as a hollow shaft and has an integrated evaluation unit that enables eddy current testing, data evaluation and wireless data transmission via LoRaWAN. The required energy is provided by an integrated generator. Functional verification of the load monitoring was performed by testing the splined shaft under alternating torsional loads.