Using a Signal Flow Analysis to Develop Prototypes of Sensing Machine Elements

A mandatory requirement for the concept of intelligent systems and of digital or cyber-physical twins is the availability of high-quality data. Therefore, the authors investigate the possibility to integrate sensors, actuators and information technologies in standardized machine elements such as screws, bearings and couplings. In this paper, the focus is on sensing machine elements, which are a sub-category of mechatronic machine elements. To gain insights about those in development as well as to verify and validate their functionality, prototypes are needed. Those prototypes should help the designer to gain knowledge about the product in development and they should preferably be developed with low efforts. Therefore, a method is proposed to analyse concepts of mechatronic machine elements, especially sensing machine elements, regarding critical aspects that may interfere with the functionality of the product. The method is based on analysing the flow of the signal that is used for the measurement, starting from its mechanical origin and ending at the analysis unit. Different examples of sensing machine elements are given in this article and the respective flow of the usable signal is analysed, leading to the identification of subsystems that can be tested individually. Based on this, prototypes for the subsystems are developed and introduced.