Chain Conveyor Wear Monitoring Using Encoder-Synced Measuring Marks
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Solution Overview
Problem
Existing chain conveyor systems in food product production plants face challenges in accurately monitoring chain wear and elongation, leading to reduced conveyor quality and potential malfunctions, as current sensor devices require complex integration and are prone to inaccuracies due to relative slippage and environmental factors.
Innovation Solution
A transport device with measuring marks attached to the chain, an electric drive system, and a position sensor, where a plant control unit correlates measurement data from a measuring sensor with position data from an absolute encoder to determine chain segment lengths, using existing components and eliminating the need for external sensors, with a clock-synchronous bus system for precise data synchronization and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensor devices are integrated into the transport device to monitor chain wear, then measurement capability is improved, but device complexity increases and mounting becomes complex
Solution Approach 1:
The chain serves itself as the measuring device by incorporating measuring marks directly onto the chain links. The chain's own structure (with attached measuring marks) is used to determine its length and wear, eliminating the need for external sensors and complex integration.
Solution Approach 2:
The chain performs multiple functions: it transports product carriers and simultaneously serves as the measuring device for monitoring its own wear and elongation through the integrated measuring marks.
2Measurement precision
If friction wheels are used to monitor chain wear, then measurement is possible, but inaccuracies occur due to relative slippage
Solution Approach 1:
The mechanical friction-based measurement system is replaced with an optical/electronic detection system. A sensor detects the passage of measuring marks attached to the chain, converting mechanical movement into electrical signals for accurate length measurement without slippage errors.
3Measurement precision
If multiple sensors are used to detect chain links, then measurement capability is improved, but ease of operation decreases as operators must read information at each measuring station
Solution Approach 1:
The sensor device provides automated feedback by detecting measuring marks and transmitting length information to a control system. This eliminates manual reading at each station and enables automated monitoring of chain wear throughout the transport device.
4Ease of operation
If visual inspection is performed regularly, then simple operation is maintained, but chain wear cannot be detected early enough to prevent malfunctions
Solution Approach 1:
The sensor device enables continuous monitoring of chain length and wear as the chain moves through the transport device, replacing intermittent visual inspection with ongoing automated measurement to detect wear early and prevent malfunctions.
Data Source
AI summary
The invention relates to a transport device (100), in particular for transporting product carriers in a plant for manufacturing food products. The transport device (100) comprises at least one chain (1) to which measuring marks (4) are attached, an electrical drive system (20) for driving the chain (1) with a servo motor (25) and an absolute encoder (21), a plant control unit (30) and a measuring sensor (11) for detecting the measuring marks (4) with a switching frequency of greater than 2000/s. The plant control unit (30) comprises a first input (34) for receiving measurement data from the measuring sensor (11) and a second input (35) for receiving position data from the position sensor (21) and is designed to receive data from the measuring sensor (11) and from the position sensor (21), to mutually correlate said data correctly with respect to time, to determine therefrom lengths between measurement marks (4), more particularly between two consecutive measurement marks, and to produce a signal which provides information about the quality of the chain. A servo position actual value is ascertained by means of oversampling.(FIG. 2)