Conveyor Chain Strain Measurement with Location Tracking
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Solution Overview
Problem
Conveyor systems face challenges in determining the layout of conveyor lines and identifying areas of high strain or chain pull without correlating measured data to specific locations, making it difficult to update facility plans and maintain equipment effectively.
Innovation Solution
A conveyor system equipped with a signal generating device, receivers, and a controller to determine the location of chain components along the conveyor line, and sensing devices to measure characteristics like temperature and strain, allowing for real-time data correlation and plotting of the conveyor line layout and high-stress areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If chain pull and strain are measured at chain links and pins, then strain data is obtained, but the data cannot be correlated to specific locations along the conveyor line
Solution Approach 1:
The system divides the conveyor chain into individual measurable segments (chain links and pins), each equipped with strain sensors. Simultaneously, the conveyor line is segmented into measurable sections using transceivers positioned at intervals, allowing location correlation of strain data from specific chain components to specific geographic locations along the conveyor path.
Solution Approach 2:
Transceivers serve as intermediary devices that bridge the gap between chain components and the control system. Each transceiver is positioned at a known location along the conveyor line and communicates with controllers to establish location references. Strain sensors on chain components communicate their readings through this intermediary network, enabling correlation of strain measurements with specific locations via the transceiver-location-controller communication chain.
2Adaptability or versatility
If conveyor line layout changes are made over time, then the conveyor system adapts to new requirements, but the original plans and facility drawings become outdated and difficult to update
Solution Approach 1:
The system implements continuous feedback by automatically measuring and recording the actual positions of chain components along the conveyor line using transceivers and strain sensors. This real-time location data is fed back to the control system, which maintains an updated digital representation of the conveyor line layout. When repositioning occurs, the system automatically detects and records the new positions, keeping facility plans current without manual intervention.
Solution Approach 2:
The patent replaces manual surveying and drawing update processes with an automated electronic measurement and data processing system. Instead of physically measuring and manually updating facility drawings, the system uses transceivers, strain sensors, and controllers to automatically track conveyor line positions and maintain accurate digital records, eliminating the need for manual plan updates.
3Measurement precision
If strain sensors are installed on chain components, then strain data is collected, but the complexity of the system increases
Solution Approach 1:
The system merges multiple measurement functions into integrated sensor units. Strain sensors and temperature sensors are combined on the same chain components, and transceivers are integrated with the sensor systems. This consolidation reduces the number of separate devices needed and simplifies the overall system architecture while maintaining comprehensive measurement capabilities.
Solution Approach 2:
The transceiver devices serve multiple functions: they act as location markers for positioning, communication nodes for data transmission, and reference points for correlating strain measurements with geographic locations. The strain sensors simultaneously measure both strain and temperature conditions. This multi-functionality reduces the need for separate dedicated devices for each measurement type, thereby reducing overall system complexity.
Data Source
AI summary
A conveyor system includes a conveyor line, a conveyor chain movable along the conveyor line, and an electronic device located at a movable component that moves with the chain along the conveyor line. The electronic device may comprise a locating device operable to generate a locating output indicative of a location of the movable component along the conveyor line. Optionally, the electronic device may comprise a sensing device operable to sense a chain characteristic at the component and to generate a sensor output indicative of the chain characteristic. Data collected by the electronic device may be stored at the device and/or transmitted to a controller of the conveyor line. The controller may be operable to determine the chain characteristic at a particular location of the transmitting device in response to the device output.