Abstract:
The development of a smart safety system was presented for real-time monitoring of grease
levels in vehicle tie rod ends, which are considered critical components responsible for maintaining
steering stability and overall road safety. Traditional vehicle maintenance was based
on scheduled inspections, which often failed to detect early signs of grease depletion, resulting
in unexpected mechanical failures, costly repairs, and potentially hazardous driving conditions.
This issue was addressed through an innovative solution in which mechanical limit switches, a
custom-designed actuator, and an ESP32-based microcontroller connected to an LCD display
were integrated. Internal pressure variations within the tie rod’s rubber boot were continuously
sensed, and grease level changes were indicated, triggering real-time alerts. A field survey involving
41 professionals, including mechanics, engineers, and technicians, was conducted, and
it was revealed that over 60% of tie rod end failures were attributed to insufficient lubrication.
Data analysis and thermal calculations demonstrated that without adequate grease, heat generation
had significantly increased (from 0.768 °C to 4.8 °C), which accelerated wear and friction.
The prototype was constructed using reconditioned tie rod components and 3D-printed parts,
and grease conditions (Stable, Low, and No Grease) were successfully identified via sensor
feedback. This cost-effective system was shown to enhance predictive maintenance capabilities
and support safer driving practices through early detection and timely intervention. The service
life of steering components was extended, and vehicle reliability was improved, particularly in
high-risk, high-use environments. Future work was proposed to include wireless data transmission
and integration into onboard diagnostic systems to advance automotive safety technologies.
This research introduces a novel automated grease detection system for vehicle tie rod ends, offering
real-time monitoring, predictive maintenance, and user-friendly alerts, improving safety
compared to existing manual solutions.
