Chain Wear Sensing with Calibrated Dual-Sensor Positioning
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Solution Overview
Problem
Existing chain monitoring systems struggle with accurately determining wear and elongation due to complex relationships involving chain geometry, mechanical and metrological tolerances, and environmental factors, leading to measurement errors and unpredictable chain failure.
Innovation Solution
A method and sensor device that uses a calibration object to precisely position two sensor systems at a defined distance, allowing simultaneous detection of chain components, enabling reliable and quick detection of wear and elongation without requiring a minimum chain speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measuring systems are used to measure chain elongation, then measurement can be performed, but measurement errors occur due to irregularities in the drive system such as slippage between drive wheel and chain or wear of sprockets
Solution Approach 1:
The invention extracts the measurement function from the drive system itself. Instead of measuring chain elongation through the drive system (which introduces errors from slippage and sprocket wear), the system uses a separate sensor device that directly measures the position of chain components, eliminating the influence of drive system irregularities on measurement accuracy.
Solution Approach 2:
The sensor device acts as an intermediary between the chain and the measurement system. Rather than relying on the drive system to transmit measurement information, the sensor directly detects chain component positions and calculates elongation, serving as an independent measurement intermediary that is not affected by drive system wear or slippage.
2Measurement precision
If chain monitoring is performed using force, path, or rotation angle measurements, then wear can be determined, but the system becomes complex and requires precise matching to specific methods since measurements depend on total chain length and sprocket wear
Solution Approach 1:
The invention extracts the measurement from complex indirect methods (force, path, rotation angle) and uses direct position measurement of chain components instead. This eliminates the need for chain tensioners, rotation angle sensors, and complex calculations dependent on total chain length and sprocket wear conditions.
Solution Approach 2:
Instead of measuring wear through its effects on force, path, or rotation (indirect methods), the invention directly measures the position of chain components and calculates elongation from these positions. This inverted approach simplifies the measurement principle and reduces system complexity while improving reliability.
3Measurement precision
If two optical or inductive sensors are used to continuously measure chain length, then wear monitoring is possible, but the distance setting between sensors becomes a lengthy process requiring multiple passes due to fluctuations from sensor geometry, chain geometry, and mechanical tolerances
Solution Approach 1:
The invention performs preliminary positioning of sensors relative to a calibration object before actual measurement. By using a calibration object with known dimensions, the sensor distance is pre-set to the correct value, eliminating the need for lengthy iterative adjustments during installation and ensuring accurate measurements from the start.
Solution Approach 2:
The invention replaces manual iterative adjustment of sensor positions with an automated calibration process. The calibration object provides reference positions that guide sensor placement, substituting mechanical trial-and-error adjustment with a systematic calibration procedure that quickly achieves accurate positioning.
4Productivity
If sensors are positioned without calibration, then setup is quick, but positions and distances between sensors fluctuate due to sensor geometry, chain geometry, and mechanical and metrological tolerances
Solution Approach 1:
The invention performs preliminary calibration of sensor positions using a calibration object before actual operation. This pre-positioning step ensures that sensors are accurately spaced relative to each other and to the chain, eliminating positioning fluctuations while maintaining efficient setup through the use of standardized calibration procedures.
Solution Approach 2:
The calibration object serves as a self-contained reference that automatically defines the correct sensor positions. The object's known geometry provides built-in calibration information, allowing sensors to self-position accurately without requiring complex external measurement equipment or extensive manual adjustment.
Data Source
AI summary
The invention relates to a method for setting up a sensor device for monitoring the state of wear of a chain, which method comprises the steps: first positioning of the first sensor system relative to a calibration object, first positioning of the second sensor system relative to the calibration object, carrying out a first signal detection using the first sensor system, carrying out a second signal detection using the second sensor system, wherein the first signal detection using the first sensor system takes place at the same time as the first signal detection of the second sensor system.