Track Tension Monitoring for Work Machines Using Pulse RADAR
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Solution Overview
Problem
It is difficult for machine users to determine whether the tension in the tracks of a work machine has reduced, which can lead to wear of track components and limit the performance of the undercarriage system.
Innovation Solution
A system and method using sensors, such as pulse RADAR, laser displacement, ultrasound, inductive position, and linear position sensors, to monitor track tension by measuring distances and analyzing changes in tension, with a controller determining if the tension falls below a threshold and alerting operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If track tension is reduced to minimize initial installation complexity, then ease of operation is improved, but track component wear increases and reliability deteriorates
Solution Approach 1:
The system continuously monitors track tension using sensors (such as load cells or strain gauges) and provides real-time feedback to the control system. When tension deviates from the optimal range, the system automatically adjusts tensioning mechanisms to maintain proper tension levels, ensuring reliable operation without manual intervention.
Solution Approach 2:
The track tensioning system is designed to automatically self-adjust and maintain optimal tension levels through integrated sensors and actuators. The system monitors its own state and performs corrective actions without external input, enabling the undercarriage system to service itself and maintain reliability autonomously.
2Reliability
If track tension is increased to prevent component wear, then reliability is improved, but device complexity increases due to need for monitoring systems
Solution Approach 1:
The system replaces complex mechanical tensioning mechanisms with electronic sensors and control systems. Instead of using elaborate mechanical devices to maintain and adjust tension, the patent employs electronic monitoring and actuation systems that are simpler, more reliable, and easier to control programmatically.
Solution Approach 2:
The monitoring and control system serves multiple functions: it monitors track tension, detects deviations from optimal levels, determines the cause of tension changes (such as track stretch or idler migration), and controls tensioning actuators. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated solution.
3Device complexity
If manual monitoring of track tension is used, then device complexity is minimized, but loss of information occurs as operators cannot detect tension changes
Solution Approach 1:
The system introduces electronic sensors and a control system as intermediaries between the track tension state and the operator. These intermediaries continuously measure tension levels and transmit this information to the control system, which then communicates with the operator through displays or alerts, ensuring no information is lost despite the operator's inability to directly sense tension changes.
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
Ensures tracks are maintained at optimum tension, reducing wear and extending their life, and provides timely notifications for servicing to restore optimal tension.
Implementation Method 1
The sensor includes a pulse radio detection and ranging (RADAR) sensor
Implementation Method 2
The sensor includes a laser displacement sensor
Implementation Method 3
The sensor includes an ultrasound sensor
Data Source
AI summary
A system for monitoring a tension in a track of a work machine includes one or more sensors coupled to the work machine. A sensor, of the one or more sensors, is configured to obtain a distance information related to a distance between the sensor and the track of the work machine. The sensor includes a pulse Radio Detection and Ranging (RADAR) sensor. The system includes a controller including at least one memory and at least one processor. The memory is configured to store an expected distance between the sensor and the track of the work machine. The processor is configured to determine an actual distance between the sensor and the track of the work machine, based on the distance information obtained from the sensor and determine, based on the actual distance being greater than the expected distance, that the tension in the track is below a tension threshold.