Integration of Real-Time Monitoring and Fault Detection Technologies for Critical Mechanical Elements: A Technical Review

Abstract

The design and reliability of mechanical elements are fundamental aspects to ensure the proper operation of industrial systems and to prevent failures with operational, economic, and safety implications. In this context, this article aims to analyze, through a narrative literature review, the integration of real-time monitoring and fault detection technologies applied to critical mechanical elements, considering their relationship with mechanical design, wear mechanisms, and diagnostic methodologies. The methodology is based on a qualitative and analytical review of specialized sources, which enabled the examination of theoretical concepts, classifications, and technical approaches related to failure analysis, online monitoring, industrial sensors, anomaly detection, and Failure Mode and Effects Analysis (FMEA). The main findings indicate that integrating reliability-oriented mechanical design with continuous monitoring systems and structured diagnostic methodologies significantly contributes to early fault identification, reduction of catastrophic failure risks, and optimization of maintenance strategies. Furthermore, condition-based monitoring and feedback to the design process enhance decision-making and operational efficiency in industrial environments. In conclusion, the reviewed literature supports the adoption of comprehensive approaches that articulate design, monitoring, and diagnostics as a key strategy to improve the reliability and performance of critical mechanical systems.