Wear sensor

Abstract

A wear sensor (10) comprising a body (12) formed from a planar sheet of flexible material and a plurality of flexible planar arms (14) extending outwardly from the body (12) in use. Each of the arms (14) includes a plurality of arm conductors (26) such that wearing of the arms (14) wears the arm conductors (26), thereby allowing detection of wear of an industrial part on which the wear sensor (10) is secured. The body (12) is provided with first connectors (20) connected to the body conductors (28) being engageable with second connectors (21) on inner ends of the arms (14), the second connectors (21) being connected to the arm conductors (26).

Description

[0001] “WEAR SENSOR”

[0002] Field of the Invention

[0003]

[0001] The present invention relates to a sensor for detecting wear in industrial parts.

[0004] Background to the Invention

[0005]

[0002] Monitoring wear in industrial components is significant both in terms of preventing failures in the equipment and scheduling appropriate maintenance in a way that reduces downtime costs. One particular example is monitoring the wearing of wear plates used to line transfer chutes in conveyor systems. The transfer chutes are lined with plates which will wear over time and eventually need to be replaced. Given the significant expense of shutdowns of such large systems, it is particularly important to ensure that the wearing parts are replaced before the wear becomes too great but not any more often than is necessary.

[0006]

[0003] Present systems utilise sensors positioned on the wearing components to detect wear. In one such system, conductors are inserted through apertures in the wearing part such that wearing of the part causes wearing of the conductors over time. The conductors extend back to a central unit on the rear of the part which provides connection to a monitoring system. Using a relatively large number of sensors can provide useful information regarding wear patterns which can enhance analysis in a way which can lead to significant operational cost savings. However, installing a large number of sensors and connection back to the central unit can be relatively time consuming.

[0007]

[0004] Using a single flexible unit having a plurality of arms which can be inserted into the wearing part can make both manufacture of the wear sensor and installation into the wearing part more effective. However, in the case of many such wearing parts, the installation of the wear sensor is completed during construction of the part which may require heat. For example, some wearparts comprise a series of wear resistant tiles bonded together with a more flexible material. The heat treatment of such wearing parts can create relative movement between portions of the wearing part, which can potentially place stress on parts of the wear sensor.

[0008]

[0005] The present invention relates to a wear sensor designed such that it is effective in operation and relatively simple to construct and therefore more cost effective to produce in larger quantities. The wear sensor is also able to be used in a variety of configurations for different applications and also more resilient to potential relative movement of the parts of the wear sensor that may occur during installation.

[0009] Summary of the Invention

[0010]

[0006] According to one aspect of the present invention there is provided a wear sensor comprising:

[0011] a body formed from a planar sheet of flexible material;

[0012] a plurality of body conductors extending from a junction on the body; and a plurality of arms extendible outwardly from the body in use, each of the arms including a plurality of arm conductors such that wearing of the arms wears the arm conductors, thereby allowing detection of wear of an industrial part on which the wear sensor is secured;

[0013] wherein the arms each comprise a planar elongate member of a sheet of flexible material which may be bent, flexed or twisted along the length therefore to locate outer ends in a location where wear of the industrial part is to be sensed, and wherein the body is provided with first connectors connected to the body conductors being engageable with second connectors on inner ends of the arms, the second connectors being connected to the arm conductors.

[0014]

[0007] Preferably each of the arms includes an expandible portion adjacent the inner end thereof.

[0008] Preferably the expandible portions each comprise a folded section, the folded section comprising a section of the arm in which the arm is folded back on itself a plurality of times to allow expansion of the length of the arm.

[0015]

[0009] Preferably each of the first and second connectors include a plurality of connection points, the connection points on the first connector each being connected to one of the body conductors and each of the connection points on the second connector being connected to one of the arm conductors such that the connection points of the first connector each electrically connect to one of the connection points on the second connector.

[0016]

[0010] Preferably each arm includes a plurality of arm conductors extending to different positions along the length of the arm such that, as the arm wears, the arm conductors will be successively damaged from the distal end to the proximal end.

[0017]

[0011] Preferably the arm conductors and body conductors comprise conductive tracks printed on the surface of the body and the arms.

[0018]

[0012] Preferably the arm conductors are connected to a junction provided on the body, the junction providing for connection to a wear monitoring system.

[0019]

[0013] Preferably the arms are bendable at a bend location about a transverse axis, being an axis perpendicular to the longitudinal axis of the arm at the bend location, such that the bend causes the arm to extend out of the plane of the arm at that location.

[0020]

[0014] Preferably the arms are bendable at a bend location about an axis at 45 degrees to the transverse axis such that the arm turns through 90 degrees at the bend location while remaining in the same plane.

[0021]

[0015] In one embodiment, the body is rectangular and the first connectors are provided adjacent edges of the body.

[0022]

[0016] In a further embodiment, the body comprises a strip and wherein the first connectors are provided at intervals along the length of the strip on a first side surface of the body.

[0017] Preferably the strip is provided with a plurality of widened portions along the length thereof and each of the first connectors is provided on one of the widened portions.

[0023]

[0018] Preferably a plurality of strips provided such that ends thereof are located adjacent each other for connection of the junctions to a sensor control unit.

[0024] Brief Description of the Drawings

[0025]

[0019] The invention will now be described, by way of example, with reference to the following drawings, in which:

[0026]

[0020] Figure 1 is an upper perspective view of a wear sensor in accordance with the present invention;

[0027]

[0021] Figure 2 is a top view of the wear sensor of Figure 1 ;

[0028]

[0022] Figure 3a is a close up view of a portion of one of the arms of the wear sensor of Figure 1 ;

[0029]

[0023] Figure 3b is a close up view of a portion of the body of the wear sensor of Figure 1 ;

[0030]

[0024] Figure 4 is a view of arms of the wear sensor;

[0031]

[0025] Figure 5 is an upper perspective view of a second embodiment of a wear sensor in accordance with the present invention;

[0032]

[0026] Figure 6 is a top view of the wear sensor of Figure 5;

[0033]

[0027] Figure 7 is an exploded view of the wear sensor of Figure 5;

[0034]

[0028] Figure 8 is a view of the wear sensor of Figure 5 in place on an industrial part;

[0035]

[0029] Figure 9 is an upper perspective view of the wear sensor of Figure 1 where the arms include a number of bends, folds and twists for the arms to be located in different positions;

[0036]

[0030] Figure 10 is an upper perspective view of a third embodiment of a wear sensor in accordance with the present invention;

[0037]

[0031] Figure 11 a is a top view of the wear sensor of Figure 10;

[0038]

[0032] Figure 11 b is a side view of the wear sensor of Figure 10;

[0033] Figure 12 is a close up view of connection of one of the arms of the wear sensor of Figure 10;

[0039]

[0034] Figure 13 is a front view of the connection of Figure 12;

[0040]

[0035] Figure 14a is a top view of the connection of Figure 12;

[0041]

[0036] Figure 14b is a side view of the connection of Figure 12.

[0042] Detailed Description of Preferred Embodiments

[0043]

[0037] Referring to the Figures, there is shown a wear sensor 10 comprising generally a planar body 12 and a plurality of elongate arms 14. The body 12 comprises a flexible planar sheet of material. In the embodiment shown in Figures 1 to 8, the body 12 is generally rectangular and therefore has first and second opposed sides 16 and 17 and first and second opposed ends 18 and 19. It will be appreciated however that alternative shapes for the body 12 of the wear sensor 10 may be used. The body 12 may be formed from a solid sheet of material, or may comprise a planar frame (not shown) having openings therein.

[0044]

[0038] The body 12 is formed from a material on which a plurality of body conductors 28 may be provided. The body conductors 28 preferably comprise conductive tracks printed on a surface of the body 12. The body 12 is also formed from a sheet material having the ability to flex, bend and to be folded.

[0045]

[0039] Each of the arms 14 comprises a relatively thin elongate member formed from a planar material. The arms 14 are also formed from a thin sheet of material having the ability to flex, bend and to be folded. Each arm 14 includes a plurality of arm conductors 26 extending along the length of the arm 14. Each of the arm conductors 26 in the embodiment shown comprises a conductive track formed in a loop out along the length of the arm 14. The arm conductors 26 on the arms 14 extend to different positions along the lengths of the arm 14. The arms 14 include a coating on outer surfaces thereof in order to not be in direct contact with wearing part to allow improved bonding with the part.

[0040] The body 12 is provided with a plurality of first connectors 20. In the embodiment of Figures 1 to 7, the first connectors 20 are provided around the periphery of the body. The first connectors 20 include a plurality of connection points, each connected to one of the body conductive tracks 28 on the body 12. Each of the arms 14 is provided with a second connector 21 at an inner end thereof. The second connectors 21 include a plurality of connection points each connected to one of the arm conductive tracks 26 on the arm 14. Engaging one of the second connectors 21 of one of the arms 14 with one of the first connectors 20 on the body 12 therefore connects the arm conductors 26 of the arm 14 with the body conductors 28 on the body 12. In the embodiment shown, a plurality of arms 14 are provided around the periphery of the body 12.

[0046]

[0041] Outer ends of the arms 14 are to be located adjacent a wear surface of a wearing part 11 on which the wears sensor 10 is installed. The outer ends of the arms 14 may be located, for example, adjacent a wear surface of a wear plate in a conveyor system. As the arm conductors 26 on each arm 14 extend to different lengths along the arm 14, as the wear surface of the wear plate wears, the distal ends of the arm 14 will wear and thereby successively break the arm conductors 26 from the outer end towards the inner end. By sending signals along the arm conductors 26 of each arm 14, it is possible to determine which arm conductors 26 have been damaged and which have not, and thereby determine the amount of wear of the surface at the location of the arm 14.

[0047]

[0042] The arm conductors 26 of each arm 14 are connected via the first and second connectors 20 and 21 and the body conductors 28 to a junction 24 on the body 12. The junction 24 is provided to allow connection of the conductors to a sensor control unit 32. The sensor control unit 32 is provided to send electrical signals on the arm conductors 26 to determine which arm conductors 26 on each arm 14 have been damaged and thereby determine the amount of wear at the location of each arm 14.

[0048]

[0043] The material from which the arms 14 are formed allows the arms 14 to flex and to also be folded or twisted at one or more bend locations along the length. The arms 14 may be bent at a bend locations about a transverse axis, being an axis perpendicular to the longitudinal axis of the arm 14 at the bendlocation, such that the bend causes the arm to extend out of the plane of the arm 14 at that location. Also, the arms 14 may be bent at a bend location about an axis at 45 degrees to the transverse axis, such that the arm 14 turns through 90 degrees at the bend location while remaining in the same plane. The flexible nature of the arms 14 also allows the arms 14 to be bent or curved at other angles, or twisted, as can be seen in Figure 9.

[0049]

[0044] Due to the flexible nature of the arms 14, it will be appreciated that the arms 14 may be curved, twisted or rolled into different positions to suit the industrial application.

[0050]

[0045] Each of the arms 14 may be constructed with one or more comers 22 along the length thereof. The corners 22 in the embodiment shown are each 90 degrees, however it will be appreciated that other angles would be possible. The corners 22 allow for a longer length of the arms 14 contained within a smaller overall space. The arms 14 may still however be extended outwardly from the configuration at construction by the use of the bends described above.

[0051]

[0046] The arrangement of the flexible body 12 and arms 14 allows the wear sensor 10 to be moved into a variety of configurations in order to locate the ends of the arms 14 at the correct location to sense wear of the industrial part on which the wear sensor is mounted. The arms 14 may also be specifically configured for use with a particular industrial part while still using a common body 12 configuration. The arms 14 may also be replaced by disconnection from the body 12 if not functioning correctly or damaged. Further, as the body 12 is flexible, the body 12 may also be bent and formed around a non-planar location on an industrial part. Figure 8 shows an example where the body 12 is bent around a corner. The body 12 may also be engaged around a curved surface of a part.

[0052]

[0047] Each of the arms 14 includes an expandible portion 30 location adjacent the inner end thereof. The expandible portions 30 are provided to allow expansion of arms 14 adjacent the inner ends thereof. In the embodiment shown, the expandible portions 30 each comprise a folded section 31. The folded sections 31 each comprise a section of the arm 14 in which the arm 14is folded back on itself a plurality of times. The multiple folds in the folded section 31 can be pulled outwardly to unfold and allow lengthening of the arm 14.

[0053]

[0048] The expandible portions 30 allow for movement of arm 14, particularly when the wear sensor is installed on a wear part during manufacture of the wearing part 11. During manufacture of the wearing part, multiple arms 14 are inserted into location in the wearing part 11. The arms 14 may, for example, be inserted through holes in tiles of a wearable material bonded together by a flexible material. As the wearing part 11 is heated to set the flexible material, it is likely that movement will occur and the position of the arms 14 may change. The expandible portions 30 allow for this movement to occur with the arms 14 still being connectible to the body 12.

[0054]

[0049] Figures 9 to 13 show a second embodiment of a wear sensor 10 in accordance with the present invention. The wear sensor of Figures 9 to 13 is similar to the previous embodiment and like reference numerals are used to denote like parts.

[0055]

[0050] In the embodiment of Figures 9 to 13, the body 12 comprises a strip 13 of the flexible body material. An end of the body 12 is engaged with the sensor control unit 32, which comprises a housing 34, as can be seen in Figure 9.

[0056]

[0051] The strip 13 includes a plurality of the first connectors 20 located at intervals along the length thereof on a first side surface. Each of the arms 14 is connectable to one of the first connectors 20 via the second connectors 21 on the arm 14, as can be seen for example in Figure 11. The strip 13 configuration of the body 12 provides for convenient placement of a series of arms 14 in locations along the length of the wearing part 11. Multiple strips 13 may be connected to the sensor control unit 32 as can be seen in Figure 9, in order to provide also series of arms 14 offset laterally from each other along the length of the wearing part 11. The strip 13 is provided with a plurality of widened portions 36 at intervals along the length thereof and each of the first connectors 20 is provided in one of the widened portions 36. It will be appreciated that while the first connectors 20 on the body 12 are shown on a single side of the body12, first connectors 20 on the embodiment of Figure 9, or the earlier embodiment, may be provided on both sides of the body 12.

[0057]

[0052] Also, extension arms (not shown ) may be provided for use with the wear sensor 10. The extension arms will include the second connectors at a first end thereof and a third connector at a second end thereof. The second connector 21 will be connected to one of the first connectors 20 on the body 12 and the second connector 21 of a further arm 14 can be connected to the third connector in order to daisy chain multiple arms 14 together to provide longer arms 14 if required.

[0058]

[0053] It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention.

Claims

Claims1. A wear sensor comprising:a body formed from a planar sheet of flexible material;a plurality of body conductors extending from a junction on the body; and a plurality of arms extendible outwardly from the body in use, each of the arms including a plurality of arm conductors such that wearing of the arms wears the arm conductors, thereby allowing detection of wear of an industrial part on which the wear sensor is secured;wherein the arms each comprise a planar elongate member of a sheet of flexible material which may be bent, flexed or twisted along the length therefore to locate outer ends in a location where wear of the industrial part is to be sensed, and wherein the body is provided with first connectors connected to the body conductors being engageable with second connectors on inner ends of the arms, the second connectors being connected to the arm conductors.

2. A wear sensor in accordance with claim 1 , wherein each of the arms includes an expandible portion adjacent the inner end thereof.

3. A wear sensor in accordance with claim 2, wherein the expandible portions each comprise a folded section, the folded section comprising a section of the arm in which the arm is folded back on itself a plurality of times to allow expansion of the length of the arm.

4. A wear sensor in accordance with any one of the preceding claims, wherein each of the first and second connectors include a plurality of connection points, the connection points on the first connector each being connected to one of the body conductors and each of the connection points on the second connector being connected to one of the arm conductors such that the connection points of the first connector each electrically connect to one of the connection points on the second connector.

5. A wear sensor in accordance with any one of the preceding claims, wherein each arm includes a plurality of arm conductors extending to different positions along the length of the arm such that, as the arm wears, the arm conductors will be successively damaged from the distal end to the proximal end.

6. A wear sensor in accordance with claim 5, wherein the arm conductors and body conductors comprise conductive tracks printed on the surface of the body and the arms.

7. A wear sensor in accordance with any one of the preceding claims, wherein the arm conductors are connected to a junction provided on the body, the junction providing for connection to a wear monitoring system.

8. A wear sensor in accordance with any one of the preceding claims, wherein the arms are bendable at a bend location about a transverse axis, being an axis perpendicular to the longitudinal axis of the arm at the bend location, such that the bend causes the arm to extend out of the plane of the arm at that location.

9. A wear sensor in accordance with any one of the preceding claims, wherein the arms are bendable at a bend location about an axis at 45 degrees to the transverse axis such that the arm turns through 90 degrees at the bend location while remaining in the same plane.

10. A wear sensor in accordance with any one of the preceding claims, wherein the body is rectangular and the first connectors are provided adjacent edges of the body.

11. A wear sensor in accordance with any one of claims 1 to 9, wherein the body comprises a strip and wherein the first connectors are provided at intervals along the length of the strip on a first side surface of the body.

12. A wear sensor in accordance with claim 11 , wherein the strip is provided with a plurality of widened portions along the length thereof and each of the first connectors is provided on one of the widened portions.

13. A wear sensor in accordance with claim 11 or 12, wherein a plurality of strips provided such that ends thereof are located adjacent each other for connection of the junctions to a sensor control unit.

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