Method and system for monitoring coupling condition, data collection device, and coupling

Abstract

The present invention describes a solution for monitoring the condition of mechanical couplings, providing data relating to the state of health of the coupling by means of data such as, for example, coupling deformation, and capable of identifying and issuing alerts relating to potential operational issues that might impact machine operation. The present invention comprises at least one means for reading one or more parameters of the coupling (1), wherein said parameters are shared with a processing unit (3) that provides data relating to the state of health of the coupling (1). The present invention pertains to the fields of mechanical engineering, telemetry, and component monitoring.

Description

METHOD AND SYSTEM FOR MONITORING COUPLING CONDITION, DATA COLLECTION DEVICE AND COUPLING Field of Invention

[0001] The present invention is situated in the fields of mechanical engineering, telemetry, and component monitoring, with the aim of proposing a condition monitoring solution for couplings in operation. More specifically, the present invention describes a solution for monitoring the condition of mechanical couplings, providing health data on the coupling through data such as coupling deformation, and is capable of identifying and alerting potential operational problems that may impact machine operation. Background of the Invention

[0002] Couplings are devices used to join shafts of rotating machines, connecting a drive shaft and a driven shaft. There are several types of couplings, some of which use an elastomeric material to join the coupling hubs, such as claw couplings and flexible couplings.

[0003] Flexible couplings have an elastic center and are generally arranged between two metal hubs. They are designed to accommodate misalignments and mechanical shocks, as well as reducing vibrations and noise. Misalignment is the cause of 50% of bearing failures, as machine elements (bearings, seals, retainers, gears) are not normally prepared for the bending induced in the shaft. The use of this type of coupling, therefore, accommodates these misalignments, reducing stress and increasing the service life of machine components.

[0004] Flexible couplings generally act as a mechanical fuse in case of overloads. Therefore, the lifespan of the flexible coupling's elastic center is impacted by aspects inherent to each application, by... For example, work schedules, overloads, and the degree of misalignment that the coupling needs to accommodate all factors. Therefore, the coupling has a direct impact on the productivity of the industrial park where the machines operate. A broken or failed coupling generates unforeseen maintenance shutdowns in industries, and a chain reaction that begins within the factory but almost always entails very high costs. Labor, machine shutdowns, inventory movement, and emergency purchases of replacement parts are examples of expenses that companies must bear when equipment goes out of operation. In certain sectors, such as the food, chemical, and metallurgical industries, downtime is even more crucial. And in 24 / 7 industries, the losses are even greater.

[0005] Industrial managers lack predictability regarding coupling wear, which directly hinders their operational planning, since coupling failure cannot be determined beforehand but rather depends on each operating regime and overload. One technique that can be used to assess the coupling is visual inspection. However, this technique, besides being costly, does not guarantee high effectiveness, as some damage is not visible during inspection and, moreover, couplings are often mounted in hard-to-reach places.

[0006] In the search for the state of the art in scientific and patent literature, the following documents were found that address the topic:

[0007] The document WO2023098948A1 refers to a circuit located in the center of a coupling. This circuit uses sensors, such as strain gauges, to measure data like torque, speed, acceleration, and temperature, and transmits this information via methods like Bluetooth or others. This circuit is autonomous, without an external power source. It uses a generator that rotates with the coupling and a center of mass that remains stationary due to gravity. Thus, when the coupling is rotating, the... The generator charges a battery, and the circuit takes and transmits the measurements. The solution proposed by WO2023098948A1 directly reads the coupling deformation using strain gauges, differing from the solution of the present invention. Furthermore, it only issues alerts when it identifies a failure or imminent failure, and is not capable of predicting the health and estimated lifespan of the coupling, nor of promoting more favorable maintenance planning conditions.

[0008] Document W02025026508A2 presents a circuit designed to be placed inside a metallic coupling. This circuit monitors certain parameters, such as torque, deformation, and vibrations, using a strain gauge. The circuit is similar to that of document WO2023098948A1, but here it is mentioned that the circuit may use an electromagnetic induction method as a voltage source, where there is a winding on the outside of the coupling and a base that is not connected to the coupling, which enables induction. This reduces the mass and inertia of the assembly compared to the circuit in document WO2023098948A1. As in the previous document, W02025026508A2 directly reads the coupling deformation using strain gauges, diverging from the solution of the present invention. Furthermore, it only issues alerts when it identifies a failure or imminent failure, and is not capable of predicting the health and estimated lifespan of the coupling, nor of promoting more favorable maintenance planning conditions.

[0009] Document US11421746B2 describes a system for contactless detection of wear on a claw coupling, using the magnetic interaction between magnets fixed to the coupling. The system proposes the use of a first magnet in the first half and a second magnet in the second half, where wear causes a variation in the circumferential gap between the magnets, modifying the combined magnetic field formed by them. This change is detected by sensors, such as Hall effect sensors, positioned stationarily around the coupling. The solution also contemplates the use of additional magnets to increase accuracy, as well as the possibility of incorporating additional magnets. It measures torque and speed to distinguish wear from normal operational deformations. In contrast to the present invention, document US11421746B2 does not use a circuit inside the coupling and only issues alerts when it identifies a failure or imminent failure, thus failing to predict the health and estimated lifespan of the coupling and promote more favorable maintenance planning conditions.

[0010] Document US2024392840A1 describes a monitoring system for an elastic coupling, focusing on the integration of optical sensors to monitor the positions of the shafts within their corresponding hubs during continuous use of the coupling. It presents a DAQ data acquisition system configured to convert signals received from the sensors into signals interpretable by an FDC fault detection and classification system. The FDC system is configured for data analysis, to determine if a light intensity received from the DAQ system exceeds an intensity threshold indicating that disengagement of the coupling shafts is about to occur, and to generate an output signal that triggers an alarm and / or interrupts the operation of the semiconductor processing tool associated with the coupling when the light intensity exceeds the predefined threshold.US2024392840A1 does not mention the possibility of reading the elastic / plastic deformation of the coupling, nor does it mention an interface for displaying the data directly to a user or generating a coupling health report. Furthermore, it only issues alerts when it identifies a failure or imminent failure, and is not capable of predicting the health conditions and estimated lifespan of the coupling, nor of promoting more favorable maintenance planning conditions, thus diverging from the present invention.

[0011] Document CN118758371A presents a method and a device that monitors online and continuously the performance of an elastic coupling in a reach extender. Using a vibration sensor, the system can detect changes in vibration and motor speed through the elastic coupling, allowing data comparison in Real-time monitoring of expected performance patterns allows for the identification of potential problems before they escalate into serious issues, such as coupling cracks. The CN118758371 A solution employs a vibration sensor connected to the range extender that collects data on motor vibrations and speed and sends this information to a controller, which performs analysis using its algorithms. The method compares the collected vibration and speed data with predefined standards to verify if the elastic coupling is functioning correctly. If the data matches the predefined standards, this indicates that the coupling is functioning correctly. However, it does not describe the issuance of fault alerts or the taking of preventive or scheduled maintenance actions, differing from the present invention.

[0012] Document CN215639274U presents a device that monitors and protects elastic couplings in diesel engines, using a laser system to detect any coupling failure in real time. Aiming to prevent further engine damage, the solution alerts users upon identifying a fault. The invention consists of two flanges positioned opposite each other, each with holes that allow the passage of a laser beam, and two laser emitting devices on opposite sides of each flange, aligned with the holes. When the laser beam passes through the holes, it reaches the receiver, allowing the device to monitor the coupling's position. CN215639274U does not specify the collection of information regarding the torque or elastic / plastic deformation of the coupling itself, differing from the present invention.Furthermore, there is no description of an interface for visualizing the data or generating a health status report for the coupling, thus failing to reveal or suggest a solution capable of promoting preventive or planned maintenance actions for the coupling.

[0013] Document CN204784273U presents a tire coupling designed to detect misalignment in machines and provide a warning to the operator. The user is instructed to prevent further damage. It features a detection mechanism that illuminates an LED when the coupling is outside the predefined standard, alerting operators to the presence of a potential problem. The CN204784273U solution uses a tire ring with a detection port that works with the detection block to monitor the coupling's performance. If the coupling begins to misalign, an alert system will be activated, triggering an LED light powered by a battery. The solution proposed by CN204784273U optically reads a single parameter of the coupling and only issues an alert when it has reached a predefined value, differing from the solution of the present invention, as it is not able to predict health conditions and estimated lifespan of the coupling and promote more favorable maintenance planning conditions.

[0014] Document CN119189985A presents a method and a device that continuously monitors the performance of a range extender for a motor-generator coupling by measuring its torque and speed in real time. By comparing these measurements with predetermined limits, the system is intended to identify abnormalities in power transmission. When power generation is required, the system collects real-time data on the motor and generator, including their torque and speed. The system then compares this data with predefined limits to check for abnormalities in power generation. If the actual torque or speed of the motor or generator is outside the expected range, the system indicates a potential problem.The solution proposed by CN1 19189985A only issues an alert when the parameters read have already reached a predefined value, differing from the solution of the present invention, as it is not able to predict health conditions and estimated lifespan of the coupling and promote more favorable conditions for maintenance planning.

[0015] Thus, based on the literature reviewed, no documents were found anticipating or suggesting the teachings of the present invention, so the solution proposed here is novel and... inventive activity in relation to the state of the art.

[0016] Given this, based on current knowledge, the previous technique lacks effective solutions that would allow for an early warning of the impending failure of the coupling, as well as providing industry or machine managers with data that would enable operational predictability of their equipment equipped with couplings, allowing for precise scheduling of maintenance for this equipment. Summary of the Invention

[0017] Thus, the present invention solves the problems of the prior art by collecting data and monitoring the operating status of couplings, making it possible, for example, to collect coupling deformation data, identify potential operational problems that may impact machine operation, and generate predictive information about possible coupling failure. This monitoring assists and facilitates the efficient implementation of corrective and preventive measures, providing the machine operator or manager with predictability for incorporation into their planning and enabling preventive maintenance.

[0018] For monitoring purposes, the present invention has at least one sensor (2) that reads one or more data from the coupling (1), and the sensor (2) communicates with a processing unit (3) that processes the data read and shares it with a user of the present invention. This arrangement also allows remote and real-time monitoring of the coupling data (1).

[0019] It is an object of the invention, a method for monitoring the condition of a coupling (1) having at least one element (1.1) intended to undergo deformation comprising at least the steps of: reading usage data from the coupling (1); and generating health condition data from the coupling (1) based on the usage data collected, wherein the generation data processing is carried out by means of a processing unit (3).

[0020] It is also an object of the invention, a monitoring system for the condition of a coupling (1) having at least one element (1.1) designed to undergo deformation comprising at least: a sensor (2) for usage data of the coupling (1); and at least one processing unit (3) communicating with the sensor (2), said processing unit (3) being capable of generating health condition data of the coupling (1) based on the usage data collected.

[0021] It is another object of the invention, a device for collecting coupling data (1) having at least one element (1.1) intended to undergo deformation, wherein the coupling comprises at least two elements (1.1), wherein the device comprises at least one sensor (2) associated with the coupling (1) and a processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

[0022] It is, yet another object of the invention, a mechanical coupling (1) having at least one element (1.1) intended to undergo deformation and having at least one data collection device for said coupling (1), comprising at least two elements (1.1), at least one sensor (2) and at least one processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

[0023] It is also another object of the invention, a process for installing a device for collecting mechanical coupling data (1) and providing health condition data for that coupling (1), comprising the steps of: associating at least one sensor (2) with the coupling (1) and a processing unit (3) communicating with the sensor (2), so that the sensor (2) reads the relative movement between at least two elements (1.1) of the coupling (1) and provides the processing unit (3) with deformation data corresponding to the element most prone to deformation; and the processing unit (3) generates and provides health condition data of the coupling (1) based on collected and previously provided data.

[0024] It is also another object of the invention, a power source (5) disposed in at least one hub of the coupling (1), as illustrated by figures 2 and 3. The power source (5) comprises two rings, one being a stationary ring which is associated with the hub by bearings, while the other ring is fixed to the hub and rotates along with the movement of the coupling (1). The rings are also provided with a coil, so that the relative movement between the rings does not interfere with the transmission of energy, which occurs by electromagnetic induction. In one embodiment, the ring equipped with bearings is associated with an external power source and transmits this energy by induction to the other ring of the power source (5), which powers at least the processor (3) and the sensor (2).

[0025] These and other objects of the invention will be immediately appreciated by those skilled in the art and will be described in detail below. Brief Description of the Figures

[0026] In order to better define and clarify the content of this patent application, the following figures are presented:

[0027] Figure 1 shows a diagram of an embodiment of the system of the present invention, in which a coupling (1) is associated with a processing unit (3), which communicates with the control center (4) by means of a wireless connection.

[0028] Figure 2 shows an embodiment of the coupling (1) of the present invention, but illustrated with only one cube associated with the coupling (1) and with the power source (5) associated with that cube.

[0029] Figure 3 shows a cross-sectional view of the embodiment illustrated in Figure 2.

[0030] Figure 4 shows a concrete representation of a perspective view in cutaway of the elastic center of the coupling (1) of the present invention, showing the components of the data collection device arranged inside it.

[0031] Figure 5 shows a deformation versus number of cycles graph of an embodiment of the coupling (1) of the present invention, whose deformation was read by means of the data collection device of the present invention.

[0032] Figure 6 shows a torque versus number of cycles graph of an embodiment of the coupling (1) of the present invention, whose torque was read by means of the data collection device of the present invention.

[0033] Figure 7 shows a graph of deformation and force versus number of cycles of another embodiment of the gripper couplings (1) of the present invention, wherein the deformation and force were read by means of the data collection device of the present invention, wherein the light curves correspond to the Force readings and the dark curves correspond to the displacement readings. Detailed Description of the Invention

[0034] The present invention enables the collection of data and monitoring of the health condition of couplings (1), making it possible to identify possible operational problems during their use and facilitating the efficient taking of corrective and preventive measures. Through the health condition data of the present invention, it is possible to carry out preventive and scheduled maintenance, since the present invention is able to estimate the remaining lifespan of at least one element (1.1) of the coupling.

[0035] For the purposes of the present invention, at least one element (1.1) of the coupling (1) is intended to undergo deformation resulting from the use of this coupling (1). In one embodiment, the coupling (1) has more than one element (1.1), wherein at least one of these elements (1.1) is intended to undergo deformation resulting from the use of the coupling (1), this element (1.1) being produced from a material distinct from at least one other element (1.1).

[0036] In an embodiment where the coupling (1) is formed by at least two metal hubs associated with the aid of at least one polymeric component, as is the case with flexible tire couplings and claw couplings, the element (1.1) intended to undergo deformation is the polymeric element. In this embodiment, although the metal parts may also undergo deformation during use, their deformation value is negligible compared to the deformation suffered by the polymeric element (1.1).

[0037] For the purposes of the present invention, coupling health condition data (1) refers to any coupling data that can be read by means of suitable instrumentation and processed to obtain information about the operability of the coupling, i.e., the health condition data provides the user with information about the conditions of use of the coupling (1) and / or at least one element (1.1) of the coupling, as well as providing prediction of coupling failure (1) and / or at least one element (1.1) of the coupling, indicating an estimated service life period of that coupling (1), helping the user to adequately plan maintenance, preventing them from being surprised by sudden failures. Unlike the prior art, which alerts users when failure has already occurred or only when the parameters read reach a critical alert state, the present invention provides an estimated usage time for the coupling under real-time conditions.

[0038] For the purposes of the present invention, data relating to the coupling model (1) includes at least one of the following: torsional stiffness of the coupling (1), type of coupling (1) (i.e., claw coupling, tire coupling, etc.), diameter of the coupling (1), material of the coupling (1) and / or of at least one element (1.1) of the coupling.

[0039] In a first object, the present invention provides a method for monitoring the condition of a coupling (1) having at least one element (1.1) intended to undergo deformation comprising at least the steps of: reading coupling usage data (1); and generating coupling health condition data (1) based on the usage data collected, wherein data generation is performed by means of a processing unit (3).

[0040] In one embodiment, the processing unit (3) comprises at least one processor (3.1) embedded in the coupling (1) and at least one control unit (4), which may be located next to the coupling (1) or remote from the coupling (4). In one embodiment, the processor (3.1) sends the health data of the coupling (1) that has been generated to a control unit (4). The control unit (4), in turn, makes them available for monitoring by a user or manager, as well as storing the generated data to create a usage history of the coupling (1).

[0041] In one embodiment, the processor (3.1) is at least one of the following: a controller, microcontroller, embedded processing unit, embedded control unit, mathematical unit, as well as any other electronic or computational component capable of performing defined tasks.

[0042] In one embodiment, the control center (4) is at least one of the following: remote controller, remote processing unit, remote control unit, remote mathematical unit, as well as any other electronic or computational component capable of performing defined tasks remotely, such as, for example, in the cloud.

[0043] The coupling health condition data (1) is generated by the processing unit (3) based on two sets of data, namely coupling usage data (1) and also based on at least previously known historical data provided to the processing unit (3).

[0044] In a preferred embodiment, the control unit (4) is equipped with a model previously trained to generate coupling health condition data (1), so that, based on historical data, the said model generates coupling failure prediction data (1) or to minus one element (1.1).

[0045] In one embodiment, at least one sensor (2) is associated with the coupling (1) for reading usage data, while historical data is provided to the processing unit (3) beforehand.

[0046] In one embodiment, the coupling (1) comprises at least three elements (1.1). In a preferred embodiment, two of these elements (1.1) are hubs associated with the shafts of the machines that the coupling (1) couples, while the third element (1.1), disposed between the hubs, is the element (1.1) intended to undergo deformation, as it has less hardness than the hubs.

[0047] The processing unit (3) provides failure prediction data for at least one element (1.1) of the coupling (1). In one embodiment, the data provided to the processing unit (3) for failure prediction of at least one element (1.1) of the coupling (1) are at least one of the following: torque; strain; period; torsional stiffness of the coupling (1); coupling model (1); coupling diameter (1); coupling material (1); or a combination of the above.

[0048] In one embodiment, the historical data provided to the processing unit (3) are given as a function of the type of coupling (1), that is, when the present invention is associated with a coupling (1), this coupling (1) must be identified, and data such as its torsional stiffness, the material from which the coupling (1) is made, the model of this coupling (1) and its external diameter must then be provided. Based on such data, it is possible to access, with the aid of the control unit (4), estimated historical curves for the use of this coupling (1). Thus, by reading the usage data of the coupling (1) over time, the present invention is able to provide health condition data of the coupling (1), indicating whether the deformation suffered is within the elastic or plastic regime and even estimating the remaining useful life for this coupling (1).

[0049] In one embodiment, the coupling usage data (1), are the torque transmitted by the coupling (1) and the deformation suffered by the coupling. In one embodiment, the data are read by a sensor (2) and correspond to the relative movement between at least two elements (1.1) of the coupling (1).

[0050] For reading coupling usage data (1), reading the relative movement between at least two parts of the coupling (1) provides the processing unit (3) with at least data on: torque; deformation; or a combination of the above.

[0051] In a second object, the present invention provides a coupling (1) condition monitoring system having at least one element (1.1) designed to undergo deformation comprising at least: a sensor (2) for coupling (1) usage data; and at least one processing unit (3) communicating with the sensor (2) and capable of generating coupling (1) health condition data based on the usage data collected.

[0052] For reading deformation data, within the scope of the present invention, the sensor (2) is positioned near or in contact with the coupling (1) and is capable of collecting information or signals relating to the deformation of the coupling (1). For example, the detectors may be image capture sensors, encoders, strain gauges, accelerometers, etc., such that they are responsive to the deformation of a material or relative movement of one or more components, emitting signals relating to that deformation or movement.

[0053] In a preferred embodiment and in a non-limiting manner, the present invention comprises at least two sensors (2), wherein at least one sensor (2) reads usage data relating to the deformation of the coupling (1) while at least one other sensor (2) reads usage data relating to the torque to which the coupling (1) is subjected.

[0054] In one embodiment, at least one sensor (2) is implemented as a strain gauge and is associated with the coupling (1) for reading voltages experienced by the coupling (1), sending this data to the processor (3.1) which They convert them into torque data.

[0055] In one embodiment, at least one sensor (2) is implemented as an encoder and is associated with the coupling (1) for reading the angular displacement of the coupling (1), sending this data to the processor (3.1) which converts it into deformation data.

[0056] In one embodiment, at least one sensor (2) is an encoder fixed to an element (1.1) of the coupling (1), while a rod (2.2) passing through the encoder is fixed to another element (1.1) by means of a base (2.1). Thus, the relative movement between two elements (1.1) causes the rod (2.2) to rotate inside the sensor encoder (2), causing a usage signal that is sent to the processing unit (3) and converted into a deformation value. This value is then pre-processed and, with the aid of a wireless communication network from the processor (3.1) to the control unit (4), the health condition of the coupling is reported to a user, even being able to estimate the remaining lifespan.

[0057] In an embodiment where the coupling (1) is an elastic center coupling, known as a tire coupling, the element (1.1) intended to undergo deformation is the central polymeric portion, popularly known as the tire. The ends of this element (1.1) act as flanges where the hubs that receive the shaft of each machine whose coupling (1) will transmit torque are fixed. In this embodiment, the base (2.1) is fixed to the elastic element (1.1) next to a first hub, while the sensor (2) is fixed to the elastic element (1.1) at the opposite end, next to the second hub. The rod (2.2) extends from the center of the base (2.1) in an axial direction so that at least its end reaches the sensor (2). Thus, if there is relative movement between the two hubs, the sensor (2) will detect the rotation of the rod (2.2) and inform the processing unit (3), which is programmed to convert this relative movement into a deformation signal.Based on previously provided parameters and based on historical parameters, the processor (3.1), together with the control unit (4), are able to. convert the angular displacement of the coupling (1) into deformation and provide usage condition data of the coupling (1) to a user.

[0058] It is another object of the invention, a device for collecting coupling data (1) having at least one element (1.1) intended to undergo deformation, wherein the coupling comprises at least two elements (1.1), wherein the device comprises at least one sensor (2) associated with the coupling (1) and a processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative motion between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

[0059] It is, yet another object of the invention, a mechanical coupling (1) having at least one element (1.1) intended to undergo deformation and having at least one data collection device for said coupling (1), comprising at least two elements (1.1), at least one sensor (2) and at least one processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

[0060] Thus, based on data from opposite regions of the coupling (1), the processing unit (3) compares the information and checks if there is a difference between the information from the two regions, which may result in a failure or need for maintenance. The difference in deformation between the two sides of the coupling may indicate that there is a beginning or a propensity for wear or failure of the coupling, since the increase in the phase angle from one side to the other of the elastic center, for example, in a flexible coupling, indicates the level of deformation. The increase in this phase angle makes it possible to predict failure.

[0061] In this embodiment where the coupling (1) is a center-elastic coupling of the “tire coupling” type, the center-elastic of the element (1.1) is usually empty. Thus, this region is used to house components such as the sensor (2), the rod (2.2), the base (2.1) and the processing unit (3). In this embodiment, the processor (3.1) comprises wireless communication with the control unit (4).

[0062] For the operation of the sensors (2) and communication of the processor (3.1) with the control unit (4), a power source (5) is required. In one embodiment, and not limited to, the power source (5) is located in at least one hub of the coupling (1), as illustrated in Figures 2 and 3. In this embodiment, the power source (5) comprises two rings, one stationary ring, which is associated with the hub by bearings, while the other ring is fixed to the hub and rotates along with the movement of the coupling (1). The rings are also equipped with a coil, so that the relative movement between the rings does not interfere with the transmission of energy, which occurs by electromagnetic induction. In one embodiment, the ring equipped with bearings is associated with an external power source and transmits this energy by induction to the other ring of the power source (5), which powers the processor (3) and the sensor (2).

[0063] The coupling information is then sent to a control center (4) communicating with the processor (3.1). This control center (4) makes this information available graphically, numerically, or textually to a user or industry manager. In one embodiment, the control center (4) is an online platform with an access interface for monitoring the coupling (1). In another embodiment, the control center (4) enables intelligent monitoring of the coupling, alerting the user if it identifies a fault or a possible fault of the coupling. In yet another embodiment, the control center (4) allows the issuance of a report on the health status of the coupling (1), fault alerts, predictive alerts about the coupling (1), generation of operating and health metrics of the coupling (1), or a combination thereof.In another embodiment, the control unit (4) is provided with a visual or audible indicator that indicates the operating condition of the coupling, where said indicator. It is located remotely or close to the machine or coupling.

[0064] Thus, the present invention allows the industry or machine manager to obtain data that enables operational predictability of their equipment, which uses couplings, avoiding unwanted and unplanned maintenance and downtime. The solution proposed here facilitates the efficient implementation of corrective measures, providing the person in charge or manager of the machines with predictability for incorporation into their planning.

[0065] It is also another object of the invention, a process for installing a device for collecting mechanical coupling data (1) and providing health condition data for that coupling (1) comprising the steps of: associating at least one sensor (2) with the coupling (1) and a processing unit (3) communicating with the sensor (2), so that the sensor (2) reads the relative movement between at least two elements (1.1) of the coupling (1) and provides the processing unit (3) with deformation data corresponding to the element most prone to deformation; and the processing unit (3) generates and provides health condition data for the coupling (1) based on collected and previously provided data.

[0066] The examples shown here are intended only to illustrate one of the numerous ways of carrying out the invention, without limiting its scope. Example 1 - Flexible coupling monitoring system

[0067] The aforementioned system was implemented to monitor the deformation of a flexible coupling (1) and transmit the data, with the aid of a processing unit (3), comprising at least one processor (3.1) and a control center (4), via the internet for remote viewing. Flexible couplings (1) generally act as a kind of mechanical fuse. Tire couplings, for example, have an elastic center that accommodates any misalignments and stresses caused by the machines. Flexible couplings are formed by two hubs or side flanges. opposite ends with the elastic center located between them.

[0068] For monitoring the coupling (1), the schematization exemplified in figure 1 was carried out, which shows a flexible coupling (1) with at least one sensor (2) (not shown) positioned in order to collect data on the relative movement between at least two elements (1.1) of the coupling (1), the sensor being connected via cable to a processor (3) - in this example, a microcontroller was used.

[0069] The sensor (2), in the form of an encoder, allows the identification of the angular difference between the two sides of the coupling (1), that is, the measurement of the relative movement between one side and the other of the elastic center, in order to generate pulses relative to the deformation. The processing unit (3) calculates the pulses read, which reflects the deformation of the element (1.1) elastic center, which is practically the same deformation of the coupling (1) as a whole, since the deformation of the elastic center is significantly greater than the deformation of the metal hubs.

[0070] It is essential that this deformation be monitored over time, in order to identify its progression and indicate whether there is a beginning or a propensity for wear or failure of the coupling (1).

[0071] These data are then transmitted by the processor (3.1) to the control center (4), which is a cloud database accessible by a user. In one embodiment, the data are transmitted from the processor (3.1) to the control center (4) by wireless techniques such as, for the purposes of example and not limitation, via Wi-Fi, 4G, 5G, LoRa or similar. Example 2 - Failure prediction in flexible coupling

[0072] A method for predicting failure of the monitored coupling was also implemented. In this example, failure prediction was performed on flexible couplings, using the configuration proposed in Figures 2 to 4 for its execution.

[0073] On the bench, tests were carried out with a coupling (1) The elastic coupling, as described in the present invention, was subjected to more than 10,000 operating cycles under constant operating conditions. As illustrated in Figure 6, it can be observed that, under these tested conditions, the torque value can be considered constant over time. Although there are some oscillations, these are repeated. The graph illustrated in Figure 5 shows that the deformation value increased over time, illustrating the elastic center wearing down with use.

[0074] Thus, as summarized in Figure 7, where two graphs are superimposed, for a constant value of transmitted torque, the deformation value tends to progress over time, making it possible for the present invention to indicate the health condition of the coupling (1) and estimate its remaining service life, assisting in maintenance planning.

[0075] Based on this, a survey of historical data was carried out correlating the angular difference between the sides of the elastic center with the failure and rupture moments of the coupling (1). Thus, as the sensors (2) detect the deformations, this information is correlated with historical data and statistical indicators, to return an indication of when the coupling may rupture or fail. Both the correlation with historical data and the display of predictive failure indicators are performed in the control center (4), and are made available to the user.

[0076] The constant torque condition is quite common for various couplings (1) used in the art. However, for some applications, the torque varies during use, which causes the measured deformation to also vary. Thus, reading both parameters together is fundamental for an accurate failure prediction, since the variation in deformation over time must be related to the torque. In cases where the torque is constant, the increase in the deformation value corresponds to the natural wear and tear of the coupling (1). In situations where the torque increases, for example, there is also an increase in the measured deformation, which does not, in isolation, mean an increase in the wear of the coupling (1). Thus, the The present invention correlates deformation with torque over time to provide a more accurate and reliable coupling health condition data value (1).

[0077] The elastic center of flexible couplings (1) is normally formed by a rubber compound. As the coupling is subjected to deformation, i.e., with its use, it is possible to verify that the rubber loses its rigidity characteristics and, therefore, presents an increased possibility of failure. Thus, the proposed arrangement allows identifying the decrease in the rigidity characteristics of the rubber by associating the relative movement between the coupling hubs, which is equivalent to the deformation of the element (1.1) elastic center, being equivalent to the deformation of the coupling (1) as a whole. Example 3 - Monitoring the coupling

[0078] Alternatively or in addition to the previous examples, monitoring is performed on both new and already installed couplings.

[0079] The concept presented by the present invention allows for the installation of the monitoring system, as described previously, and the provision of data on the health status of the coupling. In the example described here, the health status is obtained through deformation data, but other types of data may be included in the system.

[0080] The availability of data in the control center (4) includes, in addition to deformation data, information useful to users or managers of industries. For example, the control center (4) provides: issuance of a report on the health status of the coupling (1), fault alerts, predictive alerts about the coupling (1), generation of operating and health metrics of the coupling (1), or a combination thereof. This information is configurable and can be obtained through the operational data of the coupling read by one or more detectors (2).

[0081] Furthermore, the data read is stored in a database that is integrated into the control center (4) or independent, but accessible by it. This database allows the generation of operational metrics of the couplings, providing this information to users as needed.

[0082] This application facilitates the operational predictability of the coupling and the machines to which it is installed, giving the user / manager the possibility to incorporate any scheduled maintenance into their planning, reducing unwanted or unplanned interruptions.

[0083] Those skilled in the art will appreciate the knowledge presented here and will be able to reproduce the invention in the forms presented and in other variants and alternatives, covered by the scope of the following claims.

Claims

Claims 1. Method for monitoring the condition of a coupling (1) having at least one element (1.1) intended to undergo deformation, characterized by comprising at least the steps of: a. reading usage data of the coupling (1); and b. generating health condition data of the coupling (1) based on the usage data collected, wherein the data generation is performed by means of a processing unit (3).

2. Method, according to claim 1, characterized in that the coupling health condition data (1) are generated by a previously trained model of the processing unit (3), wherein said model generates at least failure prediction data based on at least previously known historical data provided to the processing unit (3), which provides failure prediction data for at least one element (1.1) of the coupling (1).

3. Method, according to claim 2, characterized in that the data provided to the processing unit (3) for predicting the failure of at least one element (1.1) of the coupling (1) are at least one of: torque; deformation; period; torsional stiffness of the coupling (1); model of the coupling (1); diameter of the coupling (1); material of the coupling (1); or a combination of the foregoing.

4. Method, according to claim 1, characterized by the data reading step of coupling (1) comprising reading the relative motion between at least two parts of the coupling (1), collecting and providing to the processing unit (3) at least data of: torque; deformation; or a combination thereof.

5. Method according to claim 1, characterized in that the coupling (1) comprises at least two elements (1.1), wherein at least one element (1.1) is more prone to deformation than the other, so that that the usage data reading stage reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

6. A coupling condition monitoring system (1) having at least one element (1.1) designed to undergo deformation, characterized by comprising at least: a. a sensor (2) for coupling usage data (1); and b. at least one processing unit (3) communicating with the sensor (2) and capable of generating coupling health condition data (1) based on the usage data collected.

7. System according to claim 6, characterized in that the processing unit (3) comprises a previously trained model to generate coupling health condition data (1), wherein said model generates at least failure prediction data, based on at least previously known historical data provided to the processing unit (3).

8. System according to claim 7, characterized in that the processing unit (3) provides failure prediction data for at least one element (1.1) of the coupling (1) based on at least one of the following data: torque; deformation; period; torsional stiffness of the coupling (1); coupling model; coupling diameter (1); coupling material (1); or a combination of the foregoing.

9. System according to claim 6, characterized in that the coupling (1) comprises at least two elements (1.1), such that the sensor (2) reads the relative motion between at least two elements (1.1) and provides the processing unit (3) with at least data on: torque; deformation; or a combination thereof.

10. System according to claim 6, characterized in that the coupling (1) comprises at least two elements (1.1), wherein at least one element (1.1) is more prone to deformation than the other, such that the sensor (2) reads the relative motion between at least two elements (1.1) and provides the processing unit (3) deformation data corresponding to the element most likely to deform.

11. Coupling data collection device (1) having at least one element (1.1) intended to undergo deformation, characterized in that the coupling comprises at least two elements (1.1), wherein the device comprises at least one sensor (2) associated with the coupling (1) and a processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

12. Device, according to claim 11, characterized by comprising at least one base (2.1) fixed to at least one element (1.1) of the coupling (1), said base (2.1) being provided with a rod (2.2) that extends axially in the center of the coupling (1) towards another element (1.1), so that the sensor (2) is fixed to that other element (1.1) and associated with the end of the rod (2.2) in order to read its movement, which corresponds to the relative movement between two elements (1.1).

13. Device according to claim 11, characterized by comprising a power source (5) associated with the coupling (1) and capable of supplying the power demand for the operation of the device, wherein the power source (5) is supplied by electromagnetic induction.

14. Mechanical coupling (1) having at least one element (1.1) intended to undergo deformation and having at least one data collection device for said coupling (1), characterized by comprising at least two elements (1.1), at least one sensor (2) and at least one processing unit (3) communicating with the sensor (2), such that the sensor (2) reads the relative movement between at least two elements (1.1) and provides the processing unit (3) with deformation data corresponding to the element most likely to deform.

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