Rope-Integrated Force Sensor Assembly for Real-Time Tension Sensing
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Solution Overview
Problem
Existing rope loading systems fail to provide real-time load sensing and risk overloading, leading to rope fatigue and potential snapping, which can cause equipment damage and personnel injury.
Innovation Solution
A sensor assembly is integrated within a rope, comprising a resiliently deflectable housing with a force sensor, such as a strain gauge, and a controller, allowing for real-time tension sensing and communication via wireless networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a force sensor is integrated within a rope to enable real-time load sensing, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The force sensor is nested within a housing that is inserted into the void of the fibre rope. The housing contains the force sensor, controller, and antenna, creating a compact integrated assembly that fits inside the rope structure without requiring external mounting components.
Solution Approach 2:
The patent combines the force sensor, controller, antenna, and housing into a single integrated sensor assembly. This merging of components reduces the overall complexity by eliminating separate mounting structures and simplifying the system architecture while maintaining real-time load sensing capability.
2Reliability
If a sensor assembly is inserted into the void of a fibre rope, then the sensor is protected from environmental damage, but the housing must be resiliently deflectable to accommodate rope movement
Solution Approach 1:
The housing is designed with resiliently deflectable properties, allowing it to flex and accommodate the natural movement and deformation of the fibre rope during operation. This flexible housing structure protects the internal sensor components while adapting to the dynamic mechanical environment of the rope.
Solution Approach 2:
The housing transitions from a static rigid structure to a dynamic resilient structure that can deflect and recover. This dynamic characteristic allows the housing to respond to rope movement, tension changes, and environmental conditions while maintaining sensor protection and measurement accuracy.
3Productivity
If manual inspection of the rope is replaced by load sensing, then productivity is improved, but loss of information occurs without direct visual assessment of rope condition
Solution Approach 1:
The controller processes data from the force sensor and provides feedback about the load history and tension patterns experienced by the rope. This feedback mechanism enables automated monitoring and assessment of rope condition based on mechanical loading characteristics, complementing rather than completely replacing visual inspection insights.
Solution Approach 2:
The sensor assembly acts as an intermediary between the rope's mechanical state and the operator. By measuring and reporting load data, it provides indirect information about rope condition that complements direct visual assessment, enabling more comprehensive monitoring without requiring constant manual inspection.
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 real-time load monitoring, reducing the risk of overloading and extending the service life of ropes by providing accurate load data and enabling timely operational adjustments.
Implementation Method 1
a housing, the housing defining an interior comprising inner walling, and in which at least a portion of the housing is resiliently deflectable
Implementation Method 2
the force sensor comprises a strain gauge
Data Source
AI summary
A sensor assembly (106) for sensing tension in a rope (102) comprises an arrangement of a housing (301) and a force sensor (302) located within an interior (305) of the housing (301) to provide for repeatable, accurate data to be obtained. The force sensor (302) is non-fixedly held in contact with an inner walling (306) of the interior (305) of the housing (301), in the region of a resiliently deflectable portion (307) of the housing (301), for sensing a mechanical force applied to the resiliently deflectable portion (307). A method of sensing tension in a rope (102) comprises locating the sensor assembly (106) within the rope (102) and operating the sensor assembly (106) to sense tension in the rope (102).