Clutch Assembly Wear Detection via Optical Sensor

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Solution Overview

Problem

Existing clutch assemblies in machines face challenges in accurately and efficiently detecting friction sector wear, leading to unpredictable performance and frequent replacements, as visual inspection is time-consuming and prone to errors.

Innovation Solution

A clutch assembly with a detection device comprising a wear sensor and control unit that measures the distance between the sensor and the friction sector without contact, allowing for automatic and precise determination of wear, independent of the sensor's degradation, and includes a power unit for powering the sensor and an energy generator for reduced energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If visual inspection is used to detect friction sector wear, then no additional detection devices are needed, but the inspection is time-consuming and prone to errors

Engineering Contradiction:

Improvewear detection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual visual inspection with an automated optical detection system. The wear detection device uses optical sensors and light sources to automatically measure friction sector thickness, eliminating the need for time-consuming visual inspection by operators while providing more precise and consistent measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wear detection system enables the clutch assembly to self-monitor its own condition. The detection device automatically detects friction sector wear during operation or maintenance intervals without requiring external inspection, allowing the system to provide its own diagnostic information.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If frequent sensor replacements are performed to maintain detection accuracy, then measurement precision is maintained, but maintenance complexity and downtime increase

Engineering Contradiction:

Improvewear measurement accuracyVSAvoidsensor replacement frequency

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The detection device is designed with pre-calibrated optical paths and fixed geometric relationships between sensors and the friction sector measurement points. This preliminary setup ensures that measurements remain accurate throughout the sensor's service life without requiring frequent recalibration or replacement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs a detection system where the sensors are designed to be durable and long-lasting, contrasting with the consumable friction sectors. The detection components are built to withstand the operational environment without degrading at the same rate as the friction materials they measure, reducing replacement frequency.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If contact-based wear sensors are used, then wear detection is possible, but the sensors themselves degrade and require frequent replacement

Engineering Contradiction:

Improvewear detection capabilityVSAvoidsensor service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces contact-based mechanical wear sensors with non-contact optical detection. Light sources and optical sensors measure friction sector thickness through optical means without physically touching the friction sector, eliminating wear on the detection components themselves while maintaining reliable measurement capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces light as an intermediary medium between the detection device and the friction sector. Optical signals pass through or reflect off the friction sector material to convey thickness information without requiring direct contact between the sensor and the measured surface, thereby preventing sensor degradation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables safe, efficient, and automatic wear detection, reducing the need for frequent sensor replacements and improving maintenance efficiency by providing accurate thickness measurements of friction sectors, thus extending the operational life of the clutch assembly.

Implementation Method 1

A clutch assembly with a detection device comprising a wear sensor and control unit that measures the distance between the sensor and the friction sector without contact

Methodology Applied

Scientific EffectOptical measurement:

Data Source

PatentEP3553337B1Clutch assembly for a machine

Publication Date: 2020.10.28 GOIZPER S COOP

Figure 1A~1B
Figure 2~3
Figure 4

AI summary

Clutch assembly for a machine, comprising a clutch friction disc (1) attached to a rotating part of the machine and comprising a friction sector (1.0), and a main body coupled to a shaft of the machine and which, in a clutching position (P1), cooperates with the clutch friction disc (1) by means of friction. The clutch assembly (100) comprises a detection device configured for detecting the wear of the friction sector (1.0), is arranged in the main body, and comprises a wear sensor (6.0) for detecting a distance, and a control device (6.2) to determine the wear of the friction sector (1.0) as a function of said distance.