Smart Monitoring System for Bolt Fastening and Loosening Detection in Ground Equipment Assembly

This study presents the design, implementation, and experimental validation of an integrated fastening monitoring platform for vehicle ground equipment, aimed at supporting structural maintenance and operational safety. Rather than introducing a fundamentally new sensing principle, the work focuses on the system-level integration and verification of existing sensing, communication, and control technologies for reliable bolt loosening detection and torque-controlled pneumatic fastening. The proposed platform consists of a Smart Control Gateway (SCG), a Signal Transducer Socket (STS), and a Smart Washer Set (SWS), incorporating smart nuts and clamping-force sensing washers for M50 and M35 bolts. Sub-GHz wireless RF communication and wired RS-485 transmission are employed to provide scalable and robust connectivity among system components. The SCG hardware and firmware are fully implemented and verified, enabling continuous acquisition and transmission of fastening-state data. Experimental evaluations include functional verification, mechanical integration tests, and durability assessments. The smart washers demonstrate stable sensing performance over 100 assembly and disassembly cycles without observable degradation. The STS is validated through 200,000 impact cycles under intermittent loading conditions (3 s impact, 3 s pause), confirming its suitability for repeated industrial operation. Real-time data transmission tests verify the system’s capability to detect bolt loosening events induced by vibration or external interference. The results indicate that the proposed platform provides a practical and reliable solution for fastening-state monitoring in safety-relevant ground equipment. This work contributes validated engineering evidence for deploying integrated smart fastening systems in industrial maintenance applications and establishes a foundation for future studies on environmental robustness, false-alarm characterization, and real-time performance guarantees.