Sensor-integrated structures in mechanical engineering: challenges and opportunities for mechanical joining processes

Abstract

In recent years, the trend to extend the functionality of passive metallic structures in mechanical engineering through sensor integration has emerged. This trend is driven by the growing demand for monitoring and/or control approaches. Current state of the art sensory structures and machine elements are successfully produced by integrating sensors into metallic structures using various joining techniques. However, the widespread implementation of sensory structures and machine elements has a long way to go to be achieved. For this purpose, the sensory structures must be produced not only as standardized components, but also cost-effectively with flexible configuration of the sensory characteristics and the integration of associated electronics. This paper provides an overview of the latest joining technologies for sensory structures. A discussion of the features of each joining technique will be given. In view of the importance of force/torque measurement in load-bearing structures and machine elements, an overview will be provided on the advantages and challenges of joining processes that substitute electromechanical transducers with optical non-contact measurement techniques.