Travelling Grate Crossbeam Deformation Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods fail to effectively detect gradual deformation or damage, such as deflection and cracking, of crossbeams in travelling grates used in ore agglomerating processes, which are exposed to extreme thermal and mechanical loads, limiting foresighted maintenance and repair planning.
Innovation Solution
A contactless distance measurement method using laser reflection or other non-contact methods to monitor crossbeam deformation, combining distance measurement signals with identification signals for automatic evaluation and alerting personnel when threshold values are exceeded, allowing for proactive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical limit switches or periodic checks are used to monitor crossbeam deformation, then the monitoring system is simple and inexpensive, but gradual deformation and damage cannot be detected timely, limiting foresighted maintenance
Solution Approach 1:
The patent replaces mechanical limit switches with a laser-based optical measurement system. A laser distance sensor (e.g., inductive sensor or laser scanner) non-contactively measures the position and deformation of crossbeams, substituting mechanical contact detection with optical field-based measurement, thereby enabling continuous monitoring without mechanical wear or threshold limitations
Solution Approach 2:
The patent introduces a laser beam as an intermediary between the measurement system and the crossbeam. The laser distance sensor emits laser beams that reflect off the crossbeam surface, and the reflected beams are captured to calculate deformation. This intermediary enables non-contact measurement and eliminates the need for direct mechanical contact or complex sensor arrays
2Loss of time
If standard interval checks without monitoring means are performed, then maintenance costs are low, but deformation detection is delayed and unplanned downtime increases
Solution Approach 1:
The patent implements continuous monitoring of crossbeam deformation through the laser distance sensor, which continuously emits laser beams and measures the reflected light to track crossbeam position in real-time. This continuous measurement capability eliminates periodic inspection gaps, enabling immediate detection of deformation trends and facilitating proactive maintenance scheduling
Solution Approach 2:
The system automatically processes measurement data through evaluation units that continuously analyze deformation patterns, generate maintenance alerts, and update monitoring parameters without human intervention. The automated evaluation and alerting system enables the monitoring infrastructure to serve itself, reducing operational overhead and energy consumption compared to manual inspection protocols
3Measurement precision
If mechanical limit switches are used for alarm, then the system is simple to implement, but gradual deformation before failure cannot be detected
Solution Approach 1:
The patent replaces mechanical limit switches with a laser-based optical measurement system. A laser distance sensor (e.g., inductive sensor or laser scanner) non-contactively measures the position and deformation of crossbeams, substituting mechanical contact detection with optical field-based measurement, thereby enabling continuous monitoring without mechanical wear or threshold limitations
Solution Approach 2:
The patent transitions from one-dimensional mechanical switch detection (binary on/off at fixed threshold) to multi-dimensional optical measurement. The laser distance sensor measures crossbeam deformation in multiple spatial dimensions (X, Y, Z coordinates) and temporal dimensions (continuous time-series data), enabling comprehensive deformation analysis and trend prediction that mechanical switches cannot provide
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 continuous monitoring and timely maintenance of travelling grates by detecting deformations and damages, ensuring operational safety and reducing unplanned downtime through automatic signal processing and graphical representation of historical data.
Implementation Method 1
by means of a contactless distance measurement... a suitable apparatus for performing the method includes a means (4) for the contactless measurement of the distance of the pallet car (6), in particular of its crossbeam (6')... an acoustic or optical method with a low temperature sensitivity, e.g. an optical reflection method, preferably a laser reflection method, can be used in particular for distance measurement
Data Source
Figure 1
Figure 2
AI summary
This Invention relates to monitoring the operability of a travelling grate used for the transport of bulk material in a plant for agglomerating ores, wherein by means of a contactless distance measurement the deflection of a crossbeam of the travelling grate in a sintering machine is measured at a specified point of the path of circulation of the travelling grate, the respective crossbeam measured is identified automatically and the distance measurement value signals and the identification measurement value signals are combined for evaluation.