Sensor-Integrated Toothed Belt Powered by Conductive Tension Member
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Solution Overview
Problem
Toothed belts are often replaced prematurely or not recognized as needing replacement, leading to process standstills and significant costs due to a lack of monitoring and understanding of their condition, especially since existing solutions face challenges in reliably powering embedded electronic components under mechanical stress.
Innovation Solution
A toothed belt with an electrically conductive tension member integrated within a plastic matrix, where the tension member is used for inductive coupling to supply power to embedded electronic components, allowing for contact-free energy transfer and data collection on parameters like temperature and acceleration, enabling robust and permanent powering of sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electronic components are embedded in the toothed belt to enable condition monitoring, then measurement precision and reliability are improved, but device complexity and difficulty of manufacture increase
Solution Approach 1:
The patent combines the tension member and electrical conductor into a single integrated component. The tension member serves dual purposes: providing mechanical tensile strength to the belt and serving as the electrical conductor for power supply and signal transmission to embedded sensors. This merging eliminates the need for separate electrical wiring systems within the belt, reducing structural complexity while enabling condition monitoring.
Solution Approach 2:
The tension member is designed to perform multiple functions simultaneously: it provides mechanical support and tensioning for the belt operation, while also serving as an electrical conductor for powering electronic components and transmitting data. This multi-functionality reduces the number of separate components needed, simplifying the overall belt structure despite the addition of monitoring capabilities.
2Reliability
If separate power supply systems are added to power embedded sensors, then reliability of sensor operation is improved, but device complexity and mechanical design difficulty increase
Solution Approach 1:
The electrical conductor is merged with the tension member, creating a single component that provides both mechanical tensioning and electrical power delivery. This integration eliminates the need for separate power supply wiring, reducing the number of components and connections required, thereby simplifying the power supply system while maintaining reliable sensor operation.
Solution Approach 2:
The tension member is designed to simultaneously provide mechanical support and electrical power conduction. By making the tension member electrically conductive, it serves as both the structural element maintaining belt tension and the power delivery system for embedded sensors, eliminating the need for dedicated power supply infrastructure.
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
This solution ensures reliable and continuous powering of sensors within the toothed belt, allowing for effective monitoring of wear and mechanical stress, reducing unnecessary replacements and downtime by providing accurate condition data, and utilizing existing components to avoid additional mechanical design complexities.
Implementation Method 1
The inductive coupling of a voltage into the tension member is carried out by means external to the toothed belt, with voltage being induced in the tension member according to the operating principle of a transformer
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a toothed belt (1) with at least one tension member (1b) and a plastic matrix (1c) at least partially encasing the tension member, wherein the at least one tension member (1b) extends in the plastic matrix (1c) in a running direction of the toothed belt and wherein teeth (5) of the toothed belt are formed in the plastic matrix (1c) and transversely to the running direction, wherein the tension member (1b) is made of an electrically conductive material and wherein the plastic matrix (1c) is made of an electrically insulating material, wherein the toothed belt has at least one electronic component (1a) which is embedded in the plastic matrix (1c) and has at least one sensor which acquires data on a state parameter of the toothed belt.The at least one electronic component (1a) is coupled to the tension member (1b) via at least two voltage taps (6a, 6b) in order to tap a voltage induced in the tension member (1b) to supply the at least one electronic component (1a).