Machine element with a sensor device and method of manufacturing a machine element

Abstract

In a machine element having a hollow shaft section and having a sensor device (2) for detecting mechanical stresses affecting the hollow shaft section, the sensor device (2) is arranged in the hollow shaft section, wherein the hollow shaft section has a first radially inwardly protruding formation (12) and a second radially inwardly protruding formation and the sensor device (2) is positively connected with an axial pretension between the first radially inwardly protruding formation (12) and the second radially inwardly protruding formation (20). In a manufacturing process for the production of the machine element, in a first forming step a first radially inwardly protruding formation (12) is produced in the hollow shaft section of the machine element, in a subsequent sensor arrangement step, a sensor device (2) is fitted positively in the hollow shaft section on the first radially inwardly protruding formation (12) and the second radially inwardly projecting formation (20) is produced in the hollow shaft section in a subsequent joining step, by means of which the sensor device (2) is joined positively with an axial pretension between the first radially inwardly protruding formation (12) and the second inwardly protruding formation (20).

Claims

1. A machine element (1, 32) with a one-piece hollow shaft section and with a sensor device (2) for detecting a mechanical stress affecting the hollow shaft section, wherein the sensor device (2) is arranged in the hollow shaft section, characterized in that the hollow shaft section has a first radially inwardly protruding formation (12) and a second radially inwardly protruding formation (20) and in that the sensor device (2) is positively connected with an axial pretension between the first radially inwardly protruding formation (12) and the second radially inwardly protruding formation (20).

2. The machine element (1, 32) according to claim 1, characterized in that the first radially inwardly protruding formation (12) and/or the second radially inwardly protruding formation (20) has a stop surface (13,21) inclined at an angle to a central axis (11) of the hollow shaft section.

3. The machine element (1, 32) according to claim 1, characterized in that the first radially inwardly protruding formation (12) and/or the second radially inwardly protruding formation (20) have a constant cross-sectional area in peripheral direction.

4. The machine element (1, 32) according to claim 1, characterized in that a stop surface (13) of the first radially inwardly protruding formation (12) and/or a stop surface (21) of the second radially inwardly protruding formation (20) has a profiled surface in peripheral direction which forms an engagement with the sensor device (2).

5. (canceled)

6. The machine element (1, 32) according to one of the foregoing claims, characterized in that the sensor device (2) has a first end face (15) and/or a second end face (17) with a circumferential edge zone with a profiled shaping in the peripheral direction, which forms an engagement with the first radially inwardly protruding formation (12) or with the second radially inwardly protruding formation (20).

7. The machine element (1, 32) according to claim 6, characterized in that the circumferential edge zone of the first end face (15) and/or the second end face (17) with a profiled shaping in the peripheral direction forms a contact surface inclined at an angle to the central axis (11) and that the axial pre-tension of the sensor device (2) is predetermined by the inclined contact surface.

8. The machine element (1, 32) according to claim 1, characterized in that the sensor device (2) has a shaping of a first end face (15) and/or a second end face (17) of the sensor device (2) adapted to a shaping of the first or second radially inwardly protruding formation (12, 20).

9. The machine element (1, 32) according to claim 1, characterized in that the sensor device (2) has at least one deformation sensor (23).

10. The machine element (1, 32) according to claim 1, characterized in that the machine element is a shaft (32) or a hollow shaft (1).

11. A method for manufacturing a machine element (1, 32) having a hollow shaft section and a sensor device (2) arranged therein for measuring mechanical stress affecting the hollow shaft section, wherein in a first forming step a first radially inwardly protruding formation (12) is formed in the hollow shaft section of the machine element (1, 32), wherein in a subsequent sensor arrangement step a sensor device (2) is positively fitted in the hollow shaft section on the first radially inwardly protruding formation (12), and wherein, in a subsequent joining step, a second radially inwardly protruding formation (20) is formed in the hollow shaft section by which the sensor device (2) is positively connected with an axial pretension between the first radially inwardly protruding formation (12) and the second radially inwardly protruding formation (20).

12. The method according to claim 11, characterized in that the first radially inwardly protruding formation (12) and the second radially inwardly protruding formation (20) are produced by cold forming.

13. The method according to claim 12, characterized in that the radially inwardly protruding formations (12, 20) are produced by rotary swaging.

14. The method according to claim 11, characterized in that a profiled shaping in the peripheral direction of the first and/or the second radially inwardly protruding formation (12, 20) is predefined by a mandrel (4) inserted into the hollow shaft section.

15. The method according to claim 11, characterized in that a profiled shaping in the peripheral direction of the first and/or the second radially inwardly protruding formation (12, 20) is predefined by the profiled end faces (15, 17) of the sensor device (2).

16. A machine element, comprising: a hollow shaft section formed within the machine element; a first radially inwardly protruding formation formed within the hollow shaft section; a second radially inwardly protruding formation formed within the hollow shaft section; and a deformation sensor arranged between the first radially inwardly protruding formation and the second radially inwardly protruding formation in the hollow shaft section, wherein the sensor device is positively connected with an axial pretension between the first radially inwardly protruding formation and the second radially inwardly protruding formation, and wherein the hollow shaft section within the machine element is formed as a single piece.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The following examples of the inventive step illustrated in the drawing are explained in more detail below. It shows:

[0030] FIGS. 1 to 4 a schematic representation of a process sequence during the production of a hollow shaft with a sensor device arranged therein,

[0031] FIG. 5 a schematic representation of a machine tool for rotary swaging during processing of a hollow shaft section,

[0032] FIG. 6 an exploded view of a mandrel and a hollow-shaft section with a produced profiling using the mandrel during the manufacturing process according to the invention of the hollow shaft section, with the sensor device arranged therein,

[0033] FIG. 7 a schematic representation of a hollow shaft with a sensor device arranged therein, as well as an amplifier and transmission device,

[0034] FIG. 8 a schematic and partially sectioned representation of a sensor assembly with multiple deformation sensors in a radially recessed belt area,

[0035] FIGS. 9 and 10 each a schematic representation of various possibilities for generating a form-fit between the sensor device and the surrounding hollow shaft section, which is formed in the circumferential direction,

[0036] FIG. 11 a schematic representation of a portion of the sensor device, which is fixed positively in the peripheral direction in a surrounding region of the hollow shaft section, and

[0037] FIG. 12 a schematic representation of a different sensor arrangement having a sensor arrangement comprising a plurality of piezoelectrically contacted quartz disks, wherein the sensor arrangement is arranged in a shaft with a hollow shaft section limited in axial direction.

DETAILED DESCRIPTION

[0038] In FIGS. 1 to 4, different steps within the inventive manufacturing process are shown as examples, with which a hollow shaft 1 with a pre-tensioned sensor device 2 fixed therein is produced.

[0039] A tubular blank 3, as shown in FIG. 1, can be used for the production. A mandrel 4 is inserted into the tubular blank 3, which has a first section 5 with a slightly smaller radius and a second section 6 with a slightly larger radius. The respective end zones of the two sections 5 and 6 each have a chamfer 7 and 8 profiled in circumferential direction. The length of the first section 5 and the distance between the two chamfers 7 and 8 correspond approximately to the length of the sensor device 2 in the axial direction, whereby the sensor device 2 is expediently slightly longer.

[0040] With an appropriate machine tool 9 which is shown exemplary in FIG. 5, a first section of the blank 3, which is located on the right in FIG. 2, is reduced regarding the circumference by rotary swaging so that an outer circumference already corresponds to the desired shaping of the hollow shaft 1. With a suitable relative movement of the individual rotary swaging tools 10, which act oscillatingly on the blank 3 while the blank 3 is displaced relative to the machine tool 9 along its center axis 11, an inwardly protruding ring-shaped formation 12 is produced at a front end 12 of the mandrel 4. The material of the blank 3, flowing in the inner region, flows onto the profiled chamfer 7 of the mandrel 4, which acts as a negative form and produces a corresponding profiling of an inclined contact surface 13 of the inwardly protruding formation 12. The inclination angle of the contact surface 13 relative to the center axis 11 is approximately 21.

[0041] By machining the blank 3 with the machine tool 9, a conically tapered region 14 of the blank 3 is produced in the region of the chamfer 8 of the mandrel 4. This region 14 also has a profiling in the peripheral direction which is adapted to the profiling of chamfer 8 and is thus pre-determined.

[0042] Subsequently, the mandrel 4 is pulled out and the sensor device 2 is inserted into the blank 3 until a first end face 15 of the sensor device 2 touches the inwardly protruding formation 12. Afterwards a second mandrel 16 is inserted into the blank 3 and pressed against a second end face 17 of the sensor device 2 so that the sensor device 2 is under axial pre-tension. The second mandrel 16 has a diameter which corresponds to the diameter of the first section 5 of the mandrel 4. On the front end 18 facing the sensor device 2, the mandrel 16 also has a chamfer 19, as shown in FIG. 3. Instead of the second mandrel 16, the first mandrel 4 could also be reinserted and pressed against the second end face 17 of the sensor device 2.

[0043] The blank 3 with the sensor device 2 arranged therein is displaced relative to the machine tool 9 together with the mandrel 16, while the blank 3 is transferred to its final form of the hollow shaft 1 by the oscillating rotary swaging tools 10 over the initially conically tapered region 14. A second inwardly protruding formation 20 is formed, of which the shaping is predetermined by the second end face 17 of the sensor device 2 and the chamfer 19 of the mandrel 16. A contact surface 21 of the inwardly protruding formation 20 facing the sensor device 2 mostly retains the profiling of the conically tapered region 14, which is transferred into the second inwardly protruding formation 20. The sensor device 2 is fixed in the axial direction positively between the first inwardly protruding formation 12 and the newly formed second inwardly protruding formation 20 under the preload defined by the mandrel 16, whereby a fitting of the conically tapered region 14 to the second end face 17 leads to an additional axially directed force component or pretension in the sensor device 2. The finished hollow shaft 1 with the sensor device 2 fixed therein is illustrated in FIG. 4. As a result of the forming process and the material flow thereby forced, the sensor device 2 is constrained and compressed in the axial direction so that the pre-tension is produced or maintained during the diameter-reducing forming process.

[0044] The inclination angle of the first radially inwardly protruding formation 12 can also be predetermined differently, since the contact surface 13 can be designed exclusively with the objective of a reliable form fit. On the other hand, the inclination angle at the contact surface 21 of the second inwardly protruding formation 20 is also important with regard to the desired material flow during the forming process and for the generation of a transverse force acting in the axial direction during the radially acting rotary swaging process and should therefore expediently lie within a region between 20 and 30.

[0045] As a result of the previously formed profiling in the peripheral direction of the tapering region 14 and by a corresponding profiling of the first inwardly protruding formation 12, a positive engagement in the peripheral direction is simultaneously produced and the sensor device 2 is torque-proof fixed between the two inwardly protruding formations 12 and 20 in an interior space of the hollow shaft 1.

[0046] The sensor device 2 has a suitable sensor carrier 22 on which several deformation sensors 23 are fixated. The sensor values measured with the deformation sensors 23 can, for example, be transmitted wirelessly to an evaluation device.

[0047] In FIG. 6, the mandrel 4 and the blank 3 are shown in an exploded view by way of illustration after the manufacturing step shown in FIG. 2. The profiling of the chamfers 7 and 8 of the mandrel 4 produce a correspondingly adjusted profiling of the contact surfaces 13 and 21, between which the sensor device 2 is fixed by a form-fit in a torque-proof manner and pre-stressed in axial direction.

[0048] FIG. 7 shows by way of example the sensor device 2 fixed in the hollow shaft 1 between the two radially inwardly protruding formations 12 and 20 together with an amplifier and transmission device 24 as well as an antenna 25 for the wireless transmission of the sensor values to an external evaluation device (not shown). The amplifier and transmission device 24 is arranged directly adjacent to the sensor device 2 in the hollow shaft 1 and is electrically connected to the deformation sensors 23 on the sensor carrier 22 through the end face 15.

[0049] FIG. 8 illustrates an alternative design of the sensor device 2 in which the amplifying and transmitting device 24 is inside a cavity 26 in the interior of the sensor carrier 22. The deformation sensors 23, which are adhered to an outer peripheral surface 28 in a radially recessed belt region 27 of the sensor carrier 22, are electrically connected to the amplifier and transmission device 24. The antenna 25 is led out of the sensor carrier 22 in the axial direction through a seal 29.

[0050] In order to enable a reliable form fit in the peripheral direction with the surrounding hollow shaft 1 or with the contact surfaces 13 and 21 of the radially inwardly protruding formations 12 and 20, the sensor device 2 has a number of tooth-shaped or nose-shaped formations 30 respectively on both end faces 15 and 17.

[0051] The profiling of the contact surfaces 13 and 21 as well as the formation of tooth-shaped or nose-shaped formations 30 in the region of the end faces 15 and 17 of the sensor device 2 can be produced in various ways.

[0052] In the design example shown schematically in FIG. 9, a suitable profiling of chamfers 7 and 8 of the mandrel 4 arranged on the inside of blank 3 is used to determine an appropriate profiling of the contact surface 13 and the tapered area 14, which is then forced upon it. The two end faces 15 and 17 of the subsequently inserted sensor device 2 consist of a less hard material than the blank 3, so that its profiling is maintained during an axial press-in operation of the sensor device 2 and a subsequent shaping of the tapering region 14 and a suitable profiling of the end faces 15 and 17 of the sensor device 2 is forced.

[0053] In the exemplary design example shown in FIG. 10 the profiling on the end faces 15 and 17 of the sensor device 2 is given and transferred to the contact surfaces 13 and 21 of the radially inwardly protruding formations 12 and 20.

[0054] In both cases, a positive fit as shown in FIG. 11 is achieved, which exists in the circumferential direction between the end faces 15 and 17 and the respectively assigned contact surfaces 13 and 21 and prevents an undesirable twisting of the sensor device 2 relative to the surrounding hollow shaft 1. For the sake of illustration, only a partial region of the sensor device 2 in the illustration on the right is shown in FIG. 11. The profiling given in circumferential direction is located both on the right-hand face 15 of the sensor device 2 and on the left-hand contact surface 21 of the radially protruding shape 20, so that a form-fit intervention between sensor device 2 and the hollow shaft 1 is given, which originates respectively from both surfaces.

[0055] In the design example shown schematically in FIG. 12, the sensor device 2 is arranged in a blind hole 31 in a shaft 32. The sensor device 2 has a plurality of piezoelectric quartz plates 33 with different cutting direction planes connected in series and arranged in a row in the axial direction.