Strand Disconnection Detection via Current Ratio Measurement
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Solution Overview
Problem
Conventional methods for detecting strand disconnection in conductors, particularly in cables subjected to repeated motion in devices like industrial robots, face challenges due to the small increase in resistance value and temperature-induced variations, making early detection difficult.
Innovation Solution
A disconnection detection device that includes a branch portion with a common conducting path and branched paths connected to insulated wires, a current ratio detection unit using a magnetic sensor to measure current ratios through the branched paths, and a processing unit to detect strand disconnection based on these measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If resistance value measurement is used to detect strand disconnection, then the detection method is simple, but the measurement precision is insufficient to detect early disconnection
Solution Approach 1:
The conductor is divided into multiple insulated wires, each with multiple strands. The detection system measures current in each insulated wire separately through branched conducting paths, allowing detection of disconnection in individual strands. This segmentation enables early detection before complete conductor failure.
Solution Approach 2:
A magnetic sensor is introduced as an intermediary to detect current ratios in the branched conducting paths. The magnetic sensor converts current information into magnetic field measurements, enabling non-contact measurement of current distribution and detection of strand disconnection through changes in current ratio.
2Reliability
If resistance measurement is used, then the device complexity is low, but the reliability of early disconnection detection is poor
Solution Approach 1:
The detection system segments the conductor into multiple insulated wires and further into strands. By measuring current in each insulated wire separately through branched paths, the system can detect disconnection in individual strands, improving reliability before complete failure occurs.
Solution Approach 2:
The patent replaces the traditional resistance measurement method with a magnetic field-based current ratio measurement system. This substitution allows for more sensitive detection of strand disconnection by measuring current distribution changes rather than relying on resistance changes that are masked by temperature effects.
3Measurement precision
If resistance value is measured to detect disconnection, then the measurement method is straightforward, but the measurement precision is compromised by temperature variations
Solution Approach 1:
A magnetic sensor serves as an intermediary to measure current ratios in the branched conducting paths. This magnetic field-based measurement approach eliminates the influence of temperature variations on resistance, as the magnetic sensor detects current distribution changes directly without being affected by thermal effects on conductor resistance.
Solution Approach 2:
The patent changes the measurement parameter from resistance value to current ratio. By measuring the ratio of currents in different branched paths, the system can detect strand disconnection without being influenced by temperature-induced resistance changes, achieving temperature-independent detection.
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 high-sensitivity detection of strand disconnection, allowing for early prediction of conductor disconnection and timely replacement of cables, thereby extending their lifespan.
Implementation Method 1
a current ratio detection unit capable of detecting a ratio of currents flowing through the plurality of branched conducting paths
Data Source
AI summary
A disconnection detection device that detects strand disconnection in a plurality of insulated wires each of which includes a conductor including a plurality of strands is provided with a branch portion including a common conducting path and a plurality of branched conducting paths branching out from an end portion of the common conducting path, each of the branched conducting paths being electrically connected, at an end portion, to one end of the conductor of the corresponding insulated wire, a current ratio detection unit capable of detecting a ratio of currents flowing through the plurality of branched conducting paths, and a disconnection detection processing unit that detects the strand disconnection in the plurality of insulated wires based on a detection result of the current ratio detection unit.