Vehicle Health Monitoring and Failure Prognosis through Edge-Based Component Wear Tracking

Traditional vehicle maintenance has relied primarily on mileage-based schedules and periodic visual inspections, approaches that often fail to account for variations in driving conditions, component quality, and usage patterns. These conventional methods typically result in either unnecessary premature replacements or unexpected component failures, leading to increased operating costs and unplanned downtime. Reactive maintenance strategies prove particularly problematic for critical wear components like clutch assemblies, brake systems, and suspension parts where undetected degradation can cause secondary damage. This paper presents an advanced monitoring system that shifts from scheduled maintenance to actual condition-based servicing through real-time wear measurement. The solution implements a network of distributed sensors that directly track critical parameters: ultrasonic measurement of clutch plate thickness, resistive wear sensors for brake pads, linear potentiometers for suspension travel analysis, and current/voltage profiling for electrical components. Each monitored subsystem incorporates localized processing through automotive-grade microcontrollers that analyze wear patterns against both manufacturer specifications and adaptive operational baselines. The architecture leverages existing CAN FD networks for system integration, requiring minimal additional wiring while enabling real-time health assessment without cloud dependency. The proposed system offers significant improvements over conventional maintenance approaches by enabling timely interventions before critical failures occur. Practical implementations show the solution effectively bridges the gap between theoretical condition monitoring and real-world service applications. The technology demonstrates particular value for fleet operations and service centers, where its measurement-based approach provides actionable insights for maintenance planning. Implementation remains cost-effective through the use of standardized automotive components and existing vehicle networks, making the solution viable across various vehicle classes.