Slew Drive Torque Sensing Through Strain-Monitored Fasteners
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Solution Overview
Problem
Current slew drives lack the capability to accurately measure and monitor torque applied to external units in real-time, which is essential for effective control and maintenance, particularly in applications like solar trackers and wind turbines.
Innovation Solution
Incorporating sensors, such as electrical or optical strain gauges, into the securing devices like bolts and end plates within the slew drive to detect axial forces and generate signals indicative of torque on the worm wheel, coupled with a control device for data storage, analysis, and communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are integrated into the securing device of the slew drive, then torque measurement capability is improved, but device complexity increases
Solution Approach 1:
The sensor is integrated into the securing device that already exists in the slew drive system. The securing device serves dual purposes: mechanically securing the worm gear to the housing and sensing the axial force generated by torque on the worm wheel. This merging of functions adds measurement capability without requiring separate dedicated sensing components.
Solution Approach 2:
The securing device is transformed into a multi-functional component that simultaneously performs mechanical fastening and torque sensing. By making the securing device universal (serving both structural and sensing roles), the patent avoids adding separate components, thereby improving measurement capability while minimizing the increase in device complexity.
2Extent of automation
If a control device is added to receive and process sensor signals, then real-time monitoring capability is improved, but device complexity increases
Solution Approach 1:
The control device automatically receives, processes, and communicates torque data without requiring manual intervention. The system performs self-monitoring and self-reporting of torque conditions, enabling real-time awareness of operational status and facilitating automated control decisions.
Solution Approach 2:
The control device creates a feedback loop by continuously receiving torque sensor signals, processing the data, and communicating results for real-time monitoring and control adjustments. This feedback mechanism enables the system to respond to changing torque conditions dynamically.
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 monitoring and control of torque applied to external units, providing valuable data for operational analysis and preventing potential failures by transmitting digitized signals to motor controllers, thus enhancing the performance and reliability of slew drives.
Implementation Method 1
the sensor is configured to sense a load on the securing device in response to a torque on the worm wheel and generate a signal indicative of the torque on the worm wheel
Data Source
AI summary
A sensor is used in measuring the torque applied to a slew drive. The slew drive includes a worm gear and a worm wheel and the sensor is coupled with a securing device that is used to secure the worm gear to the slew drive housing. The sensor generates a signal which is indicative of the torque on the worm wheel. The worm gear is secured to the slew drive housing by a first bearing and a second bearing. Two end plates and eight bolts are also used to further secure the worm gear and the bearings to the slew drive housing. By tightening the bolts, a compressive force is applied on the worm gear through the bearings. The applied torque on the worm wheel causes an axial force on the worm gear. The axial force is transmitted through the worm gear, the bearings, the end plates, and the bolts. One or more sensors can be embedded in one or more of the end plates or the bolts to measure the strain, in the end plates or the bolts, due to the axial force. A control device receives the signal from the sensor and stores, analyses, and/or communicates the signal.