Crane Wheel Wear Detection With an Integrated Mechanical Gauge
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Solution Overview
Problem
Existing wheel systems, particularly those on cranes, face issues with wear detection that require disassembly or costly and less robust sensor-based solutions, leading to inefficiencies in maintenance.
Innovation Solution
A mechanical device integrated into the wheel system's support body allows for wear detection and quantification without disassembly, using a movable sensor that contacts the wheel upon manual actuation, providing a robust and cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wear detection is performed by disassembling the wheel system and breaking it down into components, then wear can be examined on the wheel, but inspection effort and time are increased
Solution Approach 1:
The patent extracts the wear detection function from the complex disassembly process by introducing a dedicated measuring device that can be mounted on the support body. This device includes a sensor and evaluation unit that specifically target wear measurement, eliminating the need to disassemble the entire wheel system while maintaining accurate wear detection capability
Solution Approach 2:
The patent introduces an intermediary measuring device as a mediator between the wheel and the inspection process. This device includes a sensor that can contact the wheel surface and an evaluation unit that processes the data, serving as an intermediate tool that enables wear detection without direct disassembly of the wheel system
2Ease of operation
If sensor-based wear detection systems are used (e.g., laser distance meters), then wear can be detected without disassembly, but system cost and operating expenses increase
Solution Approach 1:
The patent replaces complex optical sensor systems (laser distance meters) with a simpler mechanical measuring device. The new system uses a mechanical sensor that contacts the wheel surface directly, eliminating the need for complex optical components, reflectors, and control units while maintaining the ability to detect wear without disassembly
Solution Approach 2:
The patent employs a simpler, more cost-effective measuring device that can be easily manufactured and replaced if needed. The mechanical sensor and evaluation unit constitute a less expensive alternative to laser-based systems, reducing both initial investment and operating costs while achieving the same functional goal
3Measurement precision
If sensor-based systems are used for wear detection, then wear can be monitored, but robustness against mechanical influences such as vibrations decreases
Solution Approach 1:
The patent replaces sensitive optical sensors with a mechanical sensor system that is inherently more robust against vibrations. The mechanical contact-based measurement approach is less susceptible to vibration interference compared to optical systems, improving reliability in the vibratory environment of crane operations while maintaining wear detection precision
4Measurement precision
If continuous contact between sensor and wheel is maintained, then wear can be continuously monitored, but sensor wear and integrity deteriorate
Solution Approach 1:
The patent implements periodic rather than continuous contact between the sensor and the wheel. The measuring device can be brought into contact with the wheel at scheduled intervals to perform wear measurements, then retracted to a standby position. This periodic action enables effective wear monitoring while minimizing cumulative wear on the sensor and maintaining sensor integrity
Data Source
Figure 1
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Figure 2c
AI summary
The invention relates to a wheel system comprising a wheel (11) and a support body which encloses at least part of the wheel (11) and in which the wheel (11) is mounted and from which the wheel (11) projects in order to contact a rail (100). In order to enable predictive maintenance of the wheel system with low inspection requirements, according to the invention a mechanical device (20) for detecting and/or determining wear on the wheel (11) is mounted on the support body.