Elevator Tensioning Device with Load Cells
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Solution Overview
Problem
Conventional methods for detecting belt tension and misalignment in bulk material elevators are not suitable for detecting gradual changes, leading to late reactions and potential machine damage or prolonged standstills.
Innovation Solution
The elevator system incorporates a tensioning device with load cells to measure forces acting on the tensioning drum, allowing for continuous monitoring of belt tension and misalignment, with adjustable carriages and spindles to detect relative deviations and issue alarms when threshold values are exceeded, enabling early detection and prevention of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection methods (speed difference of deflection devices, inductive misalignment monitors) are used, then device complexity is reduced, but measurement precision and early detection capability deteriorate
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with a simplified load cell-based measurement system. Instead of using multiple inductive sensors and speed monitoring devices, the invention uses load cells integrated into the tensioning device to directly measure belt tension forces, thereby improving measurement precision while reducing overall system complexity
Solution Approach 2:
The load cell acts as an intermediary element between the belt tensioning system and the control system. By placing load cells in the tensioning device, the system obtains direct force measurements that mediate between the physical belt state and the electronic monitoring system, enabling precise detection without complex intermediary sensors
2Reliability
If conventional monitoring methods are used, then loss of time for detection is reduced, but reliability of early detection deteriorates
Solution Approach 1:
The load cells continuously measure belt tension from the beginning of operation, establishing a baseline force value. This preliminary measurement action enables the system to detect deviations from normal tension levels before they lead to belt failure, improving reliability while enabling early warning without time loss
Solution Approach 2:
The system implements continuous feedback by constantly monitoring load cell measurements and comparing them against threshold values or historical data. This feedback mechanism provides real-time information about belt tension changes, enabling immediate response to abnormalities and improving both reliability and reducing detection time
3Measurement precision
If load cells are integrated into the tensioning device, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent merges the measurement function with the existing tensioning device structure. Load cells are integrated into the carriage or tensioning mechanism that already exists in the elevator system, combining the mechanical tensioning function with force measurement in a single integrated component, thereby improving measurement precision without significantly increasing overall device complexity
Solution Approach 2:
The tensioning device with integrated load cells serves multiple functions: it maintains belt tension through mechanical adjustment and simultaneously provides continuous force measurement for monitoring. This multi-functionality eliminates the need for separate measurement systems, improving precision while keeping the device structure unified and manageable
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
This solution enables continuous monitoring and early detection of belt tension and misalignment, preventing damage and reducing machine downtime by providing real-time feedback and allowing for proactive maintenance.
Implementation Method 1
The tensioning device has at least one load cell (2) for measuring a force acting on the tensioning drum (42)
Data Source
Figure 1a~1c
Figure 2~3
Figure 4a~5
AI summary
The invention comprises an elevator for the vertical transport of bulk material, with a belt (9) arranged circumferentially between two vertically spaced deflection drums (41, 42), on which devices for receiving the bulk material are attached, and a drive unit (5) for rotating one of the deflection drums (41) to drive the belt (9). The elevator further comprises a tensioning device (1) for adjusting the vertical distance between the deflection drums (41, 42), wherein one of the deflection drums (42) acts as a tensioning drum, which is attached to the tensioning device (1) and by which the position of the tensioning drum (42) can be changed in the vertical direction. The tensioning device (1) has at least one load cell for measuring a force acting on the tensioning drum (42).