Spring Assembly Load Monitoring with Wireless Sensor
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Solution Overview
Problem
Resilient components, such as springs, have a limited service life due to fatigue or overload, leading to unexpected failures and costly downtimes, as their operational conditions can change unexpectedly, and existing methods lack effective monitoring for predicting failure.
Innovation Solution
A resilient assembly with a load sensor, energy supply, and wireless data transmission system that continuously monitors the spring's load, allowing for prediction of failure and remaining service life, using energy generators and rechargeable batteries for self-sufficiency, and incorporating additional sensors for environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a monitoring system with load sensor and wireless transmission is added to the spring assembly, then the prediction accuracy of spring failure is improved, but the device complexity increases
Solution Approach 1:
The patent combines the load sensor, energy storage unit, and transmitting unit into an integrated measuring assembly that is operatively connected to the spring. This merging of multiple functional components into a single coordinated system allows for comprehensive monitoring while managing complexity through functional integration rather than separate discrete components.
Solution Approach 2:
The measuring assembly serves multiple functions: it measures load values, stores energy, transmits data wirelessly, and enables prediction of spring failure. By creating a multi-functional unit that performs sensing, energy management, and communication tasks, the system achieves high reliability without proportionally increasing overall device complexity.
2Reliability
If continuous monitoring of load values is implemented, then the remaining service life prediction is improved, but the energy consumption increases
Solution Approach 1:
The transmitting unit is designed to send measured values periodically or at specific intervals rather than continuously transmitting data. This periodic transmission approach maintains accurate monitoring capabilities for predicting spring failure while significantly reducing the energy consumption of the wireless communication component.
Solution Approach 2:
The energy storage unit is rechargeable and can be recharged without contact, enabling the monitoring system to be self-sufficient. The system monitors its own energy status and manages power consumption autonomously, allowing continuous operation without external intervention while maintaining reliable prediction capabilities.
3Loss of information
If the spring assembly includes wireless transmission and monitoring components, then the information availability about spring state is improved, but the weight of the assembly increases
Solution Approach 1:
The measuring assembly is attached at a specific location on the spring where it can effectively measure load values without significantly affecting the overall spring performance or adding excessive weight. The monitoring components are localized to the necessary minimum mass required for functional operation.
4Measurement precision
If additional sensors for environmental factors are added to the spring assembly, then the measurement precision of operating conditions is improved, but the device complexity increases
Solution Approach 1:
The system proactively measures environmental factors such as temperature and humidity that affect spring performance before they cause damage. By monitoring these parameters in advance, the system can predict potential issues and alert operators before failures occur, improving measurement precision while managing complexity through preventive monitoring.
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 enables accurate prediction of spring failure, minimizing downtime by allowing for proactive replacement, reducing repair costs, and ensuring continuous operation through self-sustaining power and data storage, while being cost-effective.
Implementation Method 1
the load is determined by measuring the torsion or bending or strain of the spring by means of the load sensor, for example by means of a strain gauge (DMS) or an opto-electric sensor as load sensor
Implementation Method 2
an internal energy generator, which is part of the spring assembly, or by an external energy supplier, which supplies energy to the spring assembly without contact, preferably also over a greater distance, for example by means of electromagnetic waves
Implementation Method 3
an opto-electric sensor as load sensor
Data Source
AI summary
The invention relates to a resilient assembly (1) which, in addition to the resilient component (2), usually a simple spring (2), comprises a measuring assembly (20) having a load sensor (3) for measuring the load on the spring (2) during operation and transmitting it to a monitoring unit (50) by means of a wireless transmitting unit (4).