Developing smart safety system for real-time monitoring of the tie rod end in vehicles

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.