Design Support and Strategies for Integrating Sensing Functions into Machine Elements

Sensing functions in machine elements allow early failure prediction and enhance system reliability. The problem is that the integration of sensing functions while maintaining mechanical functions leads to a conflict of objectives between mechanical and electrical domains, which is currently not supported methodically. This paper aims to overcome this conflict by methodically supporting the design of sensing functions in machine elements using the example of bolts as a case study. The V-model as an established process model for product development is expanded by sensor specific processes and further combined with the methodology of testing to overcome the conflicts arising in the design. Patterns of testing activities are found that lead to successful sensor integration into machine elements. This case study supports engineers as a reference to gather high-quality measurement and process data, which are crucial for data-driven methods like failure prediction and enhance system reliability.