Test-driven Development to Overcome Challenges in the Design of Sensor-integrating Machine Elements

Abstract

Sensor-integrating machine elements (SiME) are essential enablers for digitization in the industry. There are major challenges in the development of SiME as an interdisciplinary mechatronic system, requiring methodical support. In this work, we address these challenges and aim to provide methods and tools by analyzing the state-of-the-art and ten ongoing projects of sensor integration in machine elements. Clustering shows similarities for example in the identification of design space or weakening of the structure. Based on this, a testdriven development process with a focus on interdisciplinary negotiations and iterations is described to overcome the challenges in developing SiME.

A Review on Sensor‐Integrating Machine Elements

“…Further research is necessary to see if the existing testing methods cover reliability assessment of SiME. [58] An overview of the methods and activities already used in the state of the art of SiME development can be found in Peters et al [59] and is summarized below: There are many state-ofthe-art methods to support product development. There is the VDI 2221 for developing technical products and systems [60] with extensions and adaptations such as the procedure model published in Matthiesen, [56] for example, or the VDI 2206 for developing mechatronic systems.…”

“…[62] In order to propose appropriate support for the development of SiME, the challenges need to be specified. Peters et al [59] clustered the challenges and found that one of the main challenges is the shared design parameters of the disciplines involved, for example, the design space volume for the sensing function. From a mechanical perspective, this design space should be as small as possible to reduce the weakening of the machine element and not change the external dimensions to preserve the primary function of the machine element.…”

Integrated Optical Deformation Measurement with TIR Prism Rods

“…Another possibility is to abandon the mechanical function of the screw and only use it as housing for a sensor [ 7 ]. Further approaches to integrate a sensor in a machine element are currently under research as part of the SPP 2305, funded by the German Research Foundation (Deutsche Forschungsgemeinschaft DFG) [ 8 , 9 ].…”