Step Chain Elongation Detection Using Non-Contact Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic conveying devices, such as escalators, face challenges in accurately detecting step chain elongation and require manual maintenance, which can be disruptive and prone to sensor damage, and existing methods for determining step chain replacement are not automated.
Innovation Solution
An automatic conveying device equipped with a sensor device that detects displacement of a movable bracket, sending warning signals for shortening or replacing the step chain based on thresholds, using non-contact sensors like laser, magnetism, or infrared light, and a processor for real-time monitoring and wireless communication for remote data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sensors with rods and springs are used to detect step chain elongation, then the device can detect elongation at certain thresholds, but the sensors are prone to damage during maintenance and cannot provide continuous detection
Solution Approach 1:
The patent replaces mechanical contact sensors (rods and springs) with non-contact sensors such as laser sensors, magnetic sensors, or infrared sensors. This substitution eliminates mechanical wear and damage while enabling continuous monitoring of the step chain's position and elongation without physical contact.
Solution Approach 2:
The patent introduces an intermediary movable bracket that is driven by the step chain and carries the non-contact sensor. This bracket translates the step chain's movement into measurable displacement, allowing indirect but continuous detection of elongation without direct contact between the sensor and the step chain.
2Measurement precision
If manual measurement methods are used to determine step chain replacement, then the gap between steps can be measured, but the process is difficult to automate and requires manual intervention
Solution Approach 1:
The patent replaces manual measurement tools and methods with automated non-contact sensing systems. The laser, magnetic, or infrared sensors continuously measure the position of the movable bracket, automatically calculating the step chain elongation and gap changes without human intervention.
Solution Approach 2:
The patent implements a feedback system where the sensor continuously monitors the movable bracket's position, the processor compares the measured displacement against predefined thresholds, and automatically generates warning signals when maintenance is needed. This closed-loop feedback enables automated decision-making for step chain replacement.
3Measurement precision
If warning signals are sent based on single-trip displacement only, then short-term elongation can be detected, but accumulative elongation and total chain wear cannot be measured
Solution Approach 1:
The patent performs preliminary action by continuously accumulating displacement data from the sensor readings. The processor maintains a running total of the movable bracket's displacement, enabling prediction of when the step chain will reach its service life limit before actual failure occurs.
Solution Approach 2:
The patent transitions from static threshold detection to dynamic accumulative monitoring. The system not only detects instantaneous displacement but also tracks the cumulative displacement over time, providing a dynamic view of the step chain's degradation process and enabling proactive maintenance scheduling.
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 accurate real-time detection of step chain elongation and uneven elongations, facilitating precise and standardized maintenance, reducing the risk of sudden device stoppages and improving operational reliability.
Implementation Method 1
the non-contact sensor is a distance sensor based on laser, magnetism or infrared light
Implementation Method 2
the non-contact sensor is a distance sensor based on laser, magnetism or infrared light
Implementation Method 3
the non-contact sensor is a distance sensor based on laser, magnetism or infrared light
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention provides an automatic conveying device and a maintenance method therefor. The automatic conveying device comprises: a fixed step drive wheel, and a step driven wheel located on a movable bracket; a step chain in transmission connection with the step drive wheel and the step driven wheel; a tensioning device that acts on the movable bracket to maintain the step chain in tension; a sensor device that detects a displacement of the movable bracket; and a processor configured to send a first warning signal when a single-trip displacement of the movable bracket exceeds a first threshold, and to send a second warning signal when a accumulative displacement of the movable bracket exceeds a second threshold. The device and method according to the present invention can accurately detect an elongation of the step chain in real time.