Manufacturing and use of novel sensoric fasteners for monitoring forming processes

Abstract This paper presents sensoric fasteners which are produced by metal forming. Sensoric fasteners enable the monitoring of pretensioning forces and operating loads in mechanical connections between components. For the gathering of combined force and torque sensor signals in individual spatial directions the sensor unit has to provide the capability to transmit loads in all directions of space. The elementary sensors are integrated into the metallic fasteners structure during manufacture. This results in an assembly of supporting structure and sensor which shows a highly reproductive and sensitive interaction between its mechanical and electrical properties. In order to evaluate this interaction calibration measurements are carried out. With the help of examinations of both stationary and transient running manufacturing processes it can be shown, that the new fasteners provide the mechanical connection between tools and machine as well as the possibility to monitor operating loads. The latter allows monitoring and analysis of process forces acting within the mechanical connections.

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