Belt Damage Sensor With Stacked Conductor Loops
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Solution Overview
Problem
Existing belt monitoring systems face challenges in detecting damage, such as longitudinal slots or cracks, with insufficient sensitivity and space efficiency, leading to potential operational disruptions if not addressed promptly.
Innovation Solution
A sensor with stacked conductor loops, each extending parallel to a sensor plane, where the second loop arrangement is orthogonally spaced from the first, enhancing signal strength without significant space increase, and using printed conductive materials for a compact design compatible with existing monitoring systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single conductor loop is used for damage detection, then the sensor occupies minimal space, but the response signal quality is insufficient for reliable damage detection
Solution Approach 1:
The patent transitions from a single-plane conductor loop to a stacked multi-layer configuration. By adding the vertical dimension (stacking conductor loops in multiple layers at different heights), the sensor achieves improved response signal quality without proportionally increasing the horizontal area, thus resolving the contradiction between measurement precision and area occupation.
Solution Approach 2:
The patent employs nested conductor loops where inner loops are positioned within the area of outer loops across multiple layers. This nesting arrangement allows multiple sensing elements to occupy overlapping horizontal footprints, effectively increasing the measurement precision through multiple signal contributions while minimizing the overall sensor area requirement.
2Measurement precision
If multiple conductor loops are placed in parallel to improve signal quality, then the response signal quality improves, but the sensor occupies significantly more space
Solution Approach 1:
Instead of placing multiple conductor loops side-by-side in the horizontal plane, the patent stacks them vertically in multiple layers. This dimensional transition allows multiple loops to contribute to signal quality while their horizontal projections overlap, thus improving measurement precision without proportionally increasing the sensor's footprint area.
Solution Approach 2:
The patent combines multiple conductor loops into a unified stacked structure where the loops are electrically connected in parallel. This merging approach allows the composite sensor to deliver improved response signal quality through combined signal contributions while the compact stacked geometry minimizes the overall area occupation compared to distributed parallel arrangements.
3Measurement precision
If conductor loops are made taller to improve signal strength, then the response signal quality improves, but the sensor height increases significantly
Solution Approach 1:
The patent redistributes the signal-strengthening function from the vertical height dimension to the horizontal stacking dimension. Instead of making individual loops taller, multiple loops are stacked at different heights, allowing each loop to remain compact while the collective arrangement provides enhanced signal quality through multiple contributions without excessive overall height increase.
Solution Approach 2:
The patent segments the signal-generating function across multiple discrete conductor loops arranged in stacked layers. Rather than relying on a single tall loop, the system divides the sensing function into multiple shorter loops positioned at different vertical levels, achieving cumulative signal strength improvement while maintaining a more compact overall height profile.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sensor achieves improved response signal quality and sensitivity, allowing for early detection of belt damage, enabling timely repair or replacement while maintaining compatibility with existing systems and minimizing installation space.
Implementation Method 1
The transmitter induces an electric and/or magnetic field in at least one conductor loop of the sensor, which is detected by the receiver as a response signal
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The invention relates to a sensor (10) for detecting damage, in particular cracks, in a belt (1), with a first and a second conductor loop arrangement (20, 30) which each extend parallel to a sensor plane (E) and are spaced apart in a height direction (H) orthogonal to the sensor plane (E).