For the validation of prototypes in mechatronics, strain and temperature measurements with a known small uncertainty are required to provide feedback in the prototype design process. This applies for example to the thermal evaluation of electric motors where operating at high-power density may lead to excessive temperatures, or to the verification of high strain levels in extensive load cycles within mechanical structures (system housing & rotating components) that may lead to fatigue issues. An inaccurate knowledge of both quantities (strain and temperature) may thus lead to excessive safety factors, over-dimensioned systems or in case of under-dimensioning; failing prototypes. The SBO project FiberMech aims at unlocking the potential of distributed strain and temperature estimation in mechatronic systems at lower cost/time and improved accuracy with respect to conventional strain gauges and thermal sensors. A more time/cost-efficient, but elaborate measurement campaign will decrease the number of design iterations and save expensive physical prototyping. To reach this objective, we aim to take advantage of a new technological opportunity, optical fiber sensors for dynamic mechatronic systems, and combine it with virtual sensing principles. High-fidelity numerical models will be created for both independent strain and temperature estimation with improved accuracy for the assessment of prototypes. In particular FiberMech will deliver tools and methods for (1) multi-physical model reduction with corresponding co-simulation scheme to yield a gain in computation time and (2) reduction of optic sensor measurement uncertainty to accurately identify strain/temperature.

The tools and methods will be developed for mechatronic products covering a broad application field: (1) estimation of mechanical inputs for multiple force components; (2) improved temperature estimation in electric motors; (3) estimation of torsional loads and bending moments for electro-mechanical rotary drivetrains. Small validation cases will also be defined with the User Group members to evaluate the feasibility of the reusable results in an industrial environment.