Roll Wheel Data Logger Wear Monitoring
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Solution Overview
Problem
Existing monitoring systems for rolls and wheels in industrial environments lack autonomy, complexity, and accuracy in tracking wear and operation conditions, particularly for surfaces subject to wear, and fail to provide secure and reliable data storage and transmission.
Innovation Solution
A roll or wheel equipped with a stiff cylindrical core, a data logger containing sensors, a processor, non-volatile memory, a wireless network interface, and a battery for monitoring and storing operational data, including rotation speed and number of revolutions, with encryption for secure transmission and autonomy to function without a receiver nearby.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is positioned on the roll or wheel to monitor operational factors, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the sensor, processor, memory, and wireless interface into an integrated monitoring system that is applied directly to the roll or wheel surface. This merging of multiple components into a single applied system reduces overall device complexity while maintaining measurement precision, as the components work together as one unified unit rather than separate systems.
Solution Approach 2:
The monitoring system is designed to autonomously monitor operational factors, process the data, and transmit information without requiring external intervention. The system includes its own processor for data analysis and wireless interface for communication, enabling it to serve itself and eliminating the need for complex external monitoring infrastructure.
2Loss of information
If operational data is stored in memory for later retrieval, then loss of information is reduced, but device complexity increases
Solution Approach 1:
The memory component is integrated with the sensor and processor into a single applied monitoring system on the roll or wheel. This combination reduces the need for separate data storage systems and simplifies the overall architecture while ensuring operational data is retained for later retrieval and analysis.
Solution Approach 2:
The memory acts as an intermediary between the sensor that collects data and the wireless interface that transmits it. This intermediate storage capability ensures data is preserved even when transmission opportunities are not available, reducing information loss while maintaining a relatively simple system structure.
3Ease of operation
If a wireless network interface is added for data transmission, then ease of operation is improved, but use of energy increases
Solution Approach 1:
The wireless interface transmits data periodically or event-driven rather than continuously, reducing energy consumption while maintaining ease of operation. The system can transmit operational data at scheduled intervals or when significant changes occur, balancing communication needs with energy conservation for the battery-powered device.
4Adaptability or versatility
If the roll surface is a fouling applied to the roll core, then adaptability is improved, but ease of repair worsens
Solution Approach 1:
The monitoring system is applied to the roll surface as a separate, removable layer rather than being integrated into the roll core structure. This allows the monitoring system to be easily removed or replaced independently of the roll itself, improving ease of repair while maintaining the adaptability of the fouling-based surface application.
Data Source
AI summary
The present invention relates to a roll or a wheel, wherein the roll or the wheel is provided with (i) a stiff, essentially cylindrical roll core or wheel core that is provided at its lateral surface with a surface that is subject to wear; (ii) a data logger, that is positioned on said roll core or said wheel core of said surface, provided with at least (a) a sensor for monitoring information relating to the operation of said roll or said wheel or said surface; (b) a processor for processing said information; (c) tangible, non-volatile memory for storing said information; (d) a wireless network interface for sending and receiving data comprising said information; (e) program data stored in said memory for controlling said processor; (g) a battery or equivalent energy source for feeding (a) and/or (b) and/or (c) and/or (d); wherein said data comprise roll or wheel related data, such as e.g. a unique serial number and/or dimensions for identification of the roll or the wheel.