Long Stator Linear Motor Wear Monitoring via Force Sensors
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Solution Overview
Problem
Long stator linear motor systems experience malfunctions due to asymmetries in air gap dimensions caused by manufacturing tolerances and operational wear, leading to uncontrolled lateral forces and normal forces that can exceed actuating forces, resulting in track switch malfunctions.
Innovation Solution
A method and apparatus for monitoring the wear of long stator linear motor systems by measuring electromagnetic and mechanical forces exerted on the motor train by the transport vehicle, using sensors to detect differential forces and compare them to permissible values, allowing for predictive maintenance and identification of faulty vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing tolerances and operational wear are present, then air gap dimensions become asymmetric, but this leads to uncontrolled lateral forces and normal forces exceeding actuating forces
Solution Approach 1:
The patent applies preliminary action by continuously monitoring air gap dimensions and wear indicators before track switch malfunction occurs. Sensors measure air gap variations and wear of magnetic reaction elements during normal operation, enabling early detection and intervention before the asymmetry leads to uncontrolled lateral forces and switch failure.
Solution Approach 2:
The patent implements feedback by using sensors to continuously measure air gap dimensions and force conditions, then feeding this information back to the control system. The control system processes this feedback to detect asymmetric wear patterns and adjusts operating parameters or alerts for maintenance before track switch malfunction occurs.
2Reliability
If continuous monitoring is implemented, then predictive maintenance is enabled, but this increases device complexity
Solution Approach 1:
The patent applies universality by designing the monitoring system to serve multiple functions: measuring air gap dimensions, detecting wear of magnetic reaction elements, monitoring lateral forces, and providing predictive maintenance alerts. This multi-functional approach consolidates what could be separate complex systems into a unified monitoring solution.
Solution Approach 2:
The patent implements self-service by enabling the motor system to autonomously monitor its own condition through integrated sensors and control systems. The system automatically detects wear, measures air gap variations, and provides feedback without requiring external inspection equipment or manual measurement tools.
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 prediction of impending malfunctions, ensuring reliable track switch operation by identifying and replacing worn vehicles before malfunctions occur, thereby increasing process reliability and reducing spontaneous errors.
Implementation Method 1
a force exerted electromagnetically and/or mechanically upon the motor train by the transport vehicle transverse to the latter's direction of transport
Implementation Method 2
a force exerted electromagnetically and/or mechanically upon the motor train by the transport vehicle
Data Source
AI summary
A method and an apparatus are described for monitoring the wear of a long stator linear motor system comprising at least one motor train with stators and at least one transport vehicle that is driven electromagnetically thereby. Due to the fact that a force exerted electromagnetically and/or mechanically upon said motor train by the transport vehicle transverse to the latter's direction of transport or a differential force exerted in such manner by the transport vehicle upon two oppositely disposed motor trains is measured using sensors, changes in the forces between the motor train and the vehicle caused by dimensional tolerances and/or wear can be detected in order to prevent a malfunction of the track switch.