Loaded Conveyor Runtime Tracking for Wear Part Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conveyor systems in roadworking machines, such as milling and asphalt paving machines, face challenges in predicting the wear and tear of components like conveyor belting, chains, and augers due to the independent operation of engine and conveyor times, leading to unpredictable maintenance needs and potential conveyor failures.
Innovation Solution
A system comprising a controller with timers and sensors that measure the operating time of conveyors under load, sending signals to notify operators or owners when wear parts are nearing the end of their useful life, allowing for timely inspection or replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conveyor operating time is tracked independently of engine operating time, then maintenance timing becomes more accurate for conveyor components, but the system complexity increases due to additional sensors and controllers
Solution Approach 1:
The patent divides the monitoring system into separate independent tracking mechanisms for engine operating time and conveyor operating time. Instead of using a single unified timer, the system segments the measurement functions so that conveyor time is tracked independently through dedicated sensors and controllers, enabling accurate maintenance scheduling for conveyor components without being conflated with engine operation cycles.
Solution Approach 2:
The patent introduces intermediary sensors and control modules that specifically monitor conveyor operation. These intermediary devices detect conveyor-specific parameters and transmit data to a central system, serving as mediators between the conveyor mechanism and the overall monitoring system. This allows independent conveyor time tracking while integrating with the existing engine monitoring infrastructure.
2Reliability
If wear parts are monitored continuously, then conveyor failures can be predicted and prevented, but the cost of monitoring systems and maintenance increases
Solution Approach 1:
The patent implements preliminary monitoring actions that track conveyor operating time and wear indicators before actual failure occurs. By continuously accumulating operational data and comparing it against predetermined thresholds or wear rates, the system enables proactive maintenance scheduling. This preliminary detection approach allows planning maintenance activities in advance, preventing catastrophic failures while optimizing maintenance resource allocation based on actual usage patterns.
3Measurement precision
If conveyor operating time is accurately measured, then component wear can be predicted, but the difficulty of detecting and measuring conveyor load conditions increases
Solution Approach 1:
The patent employs universal sensors and controllers that can detect multiple parameters simultaneously. The monitoring system is designed with multi-functional capabilities, where single devices can detect various conveyor operating conditions including load, speed, and runtime. This universal approach simplifies the measurement infrastructure while maintaining precise operating time tracking and wear prediction accuracy.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A roadworking machine includes a conveyor that is adapted to move roadworking material. The roadworking machine also includes a sensor which determines if a condition exists that is indicative of the conveyor's operating under a load, and a controller which includes at least one timer. The controller receives input information including a predetermined operating run-time for a wear part that is associated with the conveyor. The controller also receives a signal from the sensor that the conveyor is operating under load. The timer measures a period of time during which the conveyor is operating under load, and the controller compares the measured period of time that the conveyor is operating under load with the predetermined operating run-time for the wear part. If the measured time matches the predetermined operating run-time, the controller will signal the operator that the wear part should be inspected for possible replacement.