Toothed Belt Sensor Power via Conductive Tension Members
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Solution Overview
Problem
Toothed belts are often replaced prematurely or not recognized as needing replacement, leading to process stoppages and costs due to lack of monitoring and robust energy supply for embedded electronic sensors.
Innovation Solution
A toothed belt with an electrically conductive tension member embedded in an insulating plastics matrix, using inductive coupling for a robust and permanent energy supply to electronic components, allowing for condition parameter detection and wireless data transmission.
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 manufacturing difficulty 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 and conducting electrical power to the embedded sensor. This eliminates the need for separate electrical connections and reduces the complexity of embedding electronics in the toothed belt.
Solution Approach 2:
The tension member is designed to perform multiple functions simultaneously: it provides mechanical tension to maintain belt tightness, conducts electrical power to the sensor, and serves as a structural element within the toothed belt. This multi-functionality reduces the overall complexity of the system by eliminating dedicated electrical connection components.
2Reliability
If the toothed belt is monitored continuously with embedded sensors, then reliability and productivity are improved, but use of energy increases
Solution Approach 1:
The patent employs periodic inductive coupling to transfer energy to the sensor. The external inductive coupling device operates intermittently, inducing electrical current in the tension member at regular intervals. This periodic energy transfer provides sufficient power for the sensor to function while minimizing overall energy consumption compared to continuous power supply methods.
Solution Approach 2:
The sensor system is designed to harvest its own operating energy from the mechanical motion and electromagnetic fields present during toothed belt operation. The inductive coupling mechanism automatically transfers energy from the external device to the tension member without requiring additional power sources or complex power management systems.
3Reliability
If a separate electrical connection system is added to supply power to embedded sensors, then reliability of energy supply is improved, but device complexity and manufacturing precision requirements increase
Solution Approach 1:
The patent merges the electrical conductor with the tension member, eliminating the need for separate electrical connection systems. The conductor is integrated directly into the tension member structure, which simplifies the embedding process and reduces manufacturing precision requirements compared to installing separate electrical connections within the toothed belt.
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 reliable and efficient monitoring of toothed belt conditions, reducing unnecessary replacements and downtime by providing a robust energy supply and enabling data collection on wear and load, thus optimizing maintenance.
Implementation Method 1
The inductively coupling device (10) has an oscillating magnetic field which penetrates through the toothed belt (1) and induces a voltage in the tension member (1b)
Data Source
AI summary
A toothed belt includes at least one tension member and a plastics material matrix which at least partially encases the tension member. The at least one tension member extends in the plastics material matrix in a running direction and teeth of the toothed belt are formed transversely to the running direction in the plastics material matrix. The tension member is formed from an electrically conductive material and the plastics material matrix is formed from an electrically insulating material. The toothed belt has at least one electronic component which is embedded in the plastics material matrix and has at least one sensor which detects data on a condition parameter of the toothed belt. The at least one electronic component is coupled to the tension member via at least two voltage taps to tap a voltage induced in the tension member to supply the at least one electronic component with power.