Track Pad Ultrasonic Thickness Sensing Without Chain Disassembly
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Solution Overview
Problem
Current methods for measuring wear on load-bearing surfaces of track pads in heavy equipment, such as electric rope shovels, are cumbersome and may underestimate wear due to the need to disassemble the track chain assembly for ultrasonic measurements.
Innovation Solution
A track pad design with a cored-out interior structure and a planar surface underneath the load-bearing surface, allowing for non-invasive ultrasonic wear measurement without disassembling the track chain assembly, and an onboard wear measurement system using an ultrasonic probe and controller to determine the thickness of the load-bearing wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the track chain assembly is disassembled to allow access to the recess for ultrasonic probe insertion, then wear measurement can be performed, but the complexity of the measurement process increases and time is lost
Solution Approach 1:
The patent introduces an intermediary structure (the recess with measurement datum) that facilitates the ultrasonic measurement process. The recess is specifically designed to accommodate the ultrasonic probe and provide a stable measurement reference, acting as a mediator between the measurement system and the load bearing surface.
Solution Approach 2:
The measurement datum is pre-formed at the bottom portion of the recess during manufacturing, before the track pad enters service. This preliminary preparation ensures that when wear measurement is needed, the reference point is already in place and does not require additional disassembly or preparation work.
2Reliability
If the measurement datum is positioned below the first wear surface in a recess, then the measurement datum is subjected to less service wear, but the track chain assembly must be disassembled for access
Solution Approach 1:
The patent segments the track pad structure by creating a recess that separates the measurement datum from the load bearing surface. This segmentation allows the measurement datum to be protected from wear while maintaining a defined access path through the recess, enabling measurement without complete disassembly of the track chain assembly.
3Device complexity
If the top surface of the drive lug is used for wear measurement comparison, then the measurement process is simple, but wear of the drive lug surface leads to underestimation of actual wear
Solution Approach 1:
The patent extracts the measurement datum from the drive lug surface that is subject to wear, and places it instead at the bottom of the recess where it is protected from service wear. This extraction ensures that the measurement reference remains stable and accurate throughout the service life of the track pad.
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 and efficient wear measurement of track pad load-bearing surfaces, reducing unplanned downtime and improving maintenance planning by providing real-time thickness data of the load-bearing wall.
Implementation Method 1
an approximately linear transmission path may be provided that is configured to receive an ultrasonic signal, and that extends from the measurement datum to the second wear surface
Data Source
AI summary
An onboard track machine wear measurement system has an ultra-sonic probe that is attached to an undercarriage of the machine that is disposed adjacent a track chain assembly, and a controller that is in communication with the ultra-sonic probe. The controller is configured to determine the thickness of a load bearing wall of a track component of the track chain assembly.