Chain Conveyor Force Measurement via Wireless Sensor
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Solution Overview
Problem
Existing chain conveyor systems face challenges in efficiently adjusting pre-tensioning force due to interfering factors like abrasive wear, thermal expansion, and varying load conditions, with limitations in continuous measurement and wireless transmission of data for real-time control.
Innovation Solution
Integration of a measurement module with a strain gauge and wireless transmission capabilities into the chain strand, allowing for continuous measurement and adjustment of pre-tensioning force, using a communication unit that can be mobile or stationary, and enabling periodic or on-demand data collection and transmission to optimize pre-tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous measurement and wireless transmission are implemented, then real-time pre-tensioning control is improved, but battery capacity and duration of use deteriorate due to high energy consumption
Solution Approach 1:
The measurement module is activated periodically based on operational parameters such as chain speed, load conditions, or time intervals rather than continuously. This periodic activation significantly reduces energy consumption while still providing sufficient data for pre-tensioning control, resolving the contradiction between real-time control reliability and battery duration.
Solution Approach 2:
The measurement and transmission activities are dynamically adjusted based on actual operational conditions. When the chain conveyor operates under stable conditions, measurement frequency is reduced. When changes in load or speed are detected, measurement frequency increases automatically. This dynamic adaptation maintains control reliability while optimizing battery usage.
2Measurement precision
If measurement module is integrated in the chain strand, then measurement precision is improved, but device complexity worsens due to integration requirements
Solution Approach 1:
The measurement module is designed as a multi-functional integrated unit that combines strain gauge measurement, data processing, wireless transmission, and power management in a single compact device. This universal design reduces the number of separate components needed and simplifies integration into the chain strand while maintaining high measurement precision.
Solution Approach 2:
The measurement module employs a nested structure where the strain gauge is integrated within the chain link, the electronics are housed within a compact module, and the entire assembly is embedded in the chain strand. This nesting approach minimizes space requirements and simplifies integration while preserving measurement accuracy.
3Loss of information
If wireless transmission range is extended, then communication capability is improved, but energy consumption increases reducing battery life
Solution Approach 1:
A relay or intermediate communication node is introduced in the wireless transmission path. The measurement module transmits data to a nearby intermediate node with higher transmission power or better antenna characteristics, which then forwards the data to the central system. This intermediary approach extends effective communication range while keeping the energy consumption of the battery-powered measurement module low.
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
This solution allows for efficient adjustment of pre-tensioning force based on real-time data, reducing wear and optimizing chain conveyor operation, with energy-efficient data transmission and long-term battery life through strategic activation and data conditioning.
Implementation Method 1
measure the chain force, such as the pre-tensioning force, for example via a strain gauge
Data Source
AI summary
A method for pre-tensioning a chain conveyor, the method relating to a chain strand which is deflected by at least one chain wheel, wherein at least one measurement module is integrated in the chain strand and transmits data wirelessly to a communication device arranged outside the chain strand. The pre-tensioning force is adjusted according to the data collected and transmitted wirelessly by the measurement module.