Sensor-Embedded Belt Coating for Accurate Temperature Sensing
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Solution Overview
Problem
Existing drive belts in capital-intensive machinery and stationary industrial equipment face issues such as damage from high vulcanization temperatures and pressures, inhomogeneous structure due to pocket formation, and poor thermal conductivity leading to inaccurate temperature measurement and signal interference, which compromise maintenance scheduling and operational reliability.
Innovation Solution
A flexible drive belt with electronics encased in a thermally conductive elastic material containing particulate and fibrous additives, positioned on the flank side to avoid damage and interference, ensuring effective thermal conductivity and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electronics are vulcanized into the drive belt material, then the electronics are securely connected to the belt, but the high vulcanization temperatures and pressures damage the electronics
Solution Approach 1:
The belt is divided into two functional zones: a vulcanized base material providing structural strength, and a non-vulcanized elastic material layer containing the electronics that avoids thermal and pressure damage. This segmentation allows each zone to be optimized for its specific function without compromising the other.
Solution Approach 2:
A non-vulcanized elastic material layer acts as an intermediary between the vulcanized belt structure and the electronics. This intermediate layer provides mechanical coupling and thermal insulation, protecting the electronics from the harsh vulcanization process while maintaining secure connection to the belt.
2Reliability
If a pocket is formed in the drive belt material to house electronics, then the electronics are protected from damage, but the belt structure becomes inhomogeneous and damaged
Solution Approach 1:
The electronics housing is merged with the belt's elastic material layer during a single molding process, creating a seamless integration that avoids separate pocket formation. This combining approach maintains belt structure homogeneity while providing protective enclosure for the electronics.
Solution Approach 2:
The electronics are positioned and the housing is formed during the belt manufacturing process before the belt enters service. This preliminary action ensures the electronics are protected from the outset without requiring subsequent structural modifications that would compromise belt homogeneity.
3Reliability
If the electronics are positioned on the underside of the belt below the reinforcing cords, then the electronics are protected from external damage, but the belt structure is compromised and electronics can be destroyed during separation
Solution Approach 1:
The belt is manufactured as a continuous coil with embedded electronics, and then separated into individual belts without disturbing the electronics position. This copying approach allows mass production while preserving electronics integrity, avoiding the need to reposition or protect electronics during separation.
4Reliability
If conventional elastic material is used to encase the electronics, then the electronics are protected and flexible, but the thermal conductivity is poor leading to inaccurate temperature measurement
Solution Approach 1:
The elastic material encasing the electronics is formulated as a composite with enhanced thermal conductivity properties. This composite material maintains the flexibility and protective qualities of elastic materials while improving heat transfer capability for accurate temperature sensing through the belt thickness.
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
The solution provides accurate temperature measurement and reliable signal transmission without damaging the electronics, enhancing maintenance scheduling and reducing downtime by improving thermal conductivity and signal strength.
Implementation Method 1
the encasement material is made thermally conductive by incorporating particulate and fibrous additives
Implementation Method 2
a belt with integrated electronics, by means of which at least one state variable of the belt can be measured and wirelessly transmitted to a remotely arranged receiving unit
Data Source
Figure 1
Figure 2A~2C
AI summary
A belt made of a flexible material with electronics arranged therein, wherein at least one state variable of the belt can be measured by means of the electronics and wirelessly transmitted to a remotely arranged receiving unit, and wherein the electronics are coated with a thermally conductive elastic material that contains particulate and fibrous additives in a proportion of a maximum of 15 wt.% to impart thermal conductivity, and the particulate and fibrous additives are incorporated into the coating material in a ratio of 4:1 to 15:1. The inclusion of particulate and fibrous additives imparts not only improved thermal conductivity to the coating but also improved signal transmission properties.The present invention further relates to arrangements comprising such a belt, belt transport rollers, and an antenna arranged in spatial proximity to the electronics so that information can be transmitted from the electronics to the antenna during operation of the belt, as well as the use of a sensor equipped with radio technology in a belt for determining state variables of the belt, such as in particular the belt temperature.