Wear Component Monitoring via Non-Contact RFID Sensors
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Solution Overview
Problem
Current monitoring systems for milling machine wear components only detect wear when a limit is reached, providing little leeway for scheduled maintenance and leading to additional downtimes, especially with metal chisels that shield electromagnetic signals, making it difficult to read transmitters installed at wear limits.
Innovation Solution
Integration of sensors with measuring sections guided along wear directions into wear areas of milling machine components, allowing for contactless data transmission to electronic components that can be read without contact, enabling continuous monitoring of wear and timely maintenance planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If transmitters are installed close to the wear limit of chisels to detect wear, then wear detection capability is improved, but electromagnetic signal reading becomes difficult due to shielding by metallic chisels
Solution Approach 1:
The patent introduces non-contact readable electronic components (such as RFID tags) as intermediaries between the sensor and the wear component. These electronic components are attached to the wear component and can be read without direct contact, allowing the monitoring system to detect wear through changes in the electromagnetic field or signal characteristics without requiring direct reading from shielded transmitters on the metal surface
Solution Approach 2:
The patent replaces traditional contact-based or direct electromagnetic transmitters with non-contact readable electronic components. This substitution eliminates the need for direct signal transmission from metal surfaces, allowing wear detection through field interactions that are not blocked by the metallic chisel material
2Loss of time
If wear monitoring is performed continuously to enable proactive maintenance, then maintenance scheduling flexibility is improved, but system complexity and cost increase
Solution Approach 1:
The patent implements continuous wear monitoring that detects wear progression before the wear limit is reached. By continuously tracking wear parameters and predicting remaining service life, the system enables maintenance to be scheduled proactively during convenient maintenance periods rather than reactively when wear limits are exceeded, providing flexibility in maintenance planning
Solution Approach 2:
The monitoring system automatically tracks wear progression and provides wear status information without requiring manual inspection. The system self-monitors the wear component condition and communicates wear status to the control system, reducing the need for complex manual monitoring procedures while enabling proactive maintenance scheduling
3Reliability
If transmitters are installed on wear components to monitor wear, then wear detection is enabled, but the transmitters cannot be read over significant distances when installed on metallic surfaces
Solution Approach 1:
The patent uses non-contact readable electronic components as intermediaries that can be read from a distance without direct contact. These components interact with the monitoring system through electromagnetic fields that can penetrate or bypass the metallic chisel shielding, enabling reliable wear monitoring with adequate reading distances for maintenance operations
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 continuous monitoring of wear, allowing for proactive maintenance scheduling, reducing unexpected downtimes, and ensuring high milling quality while minimizing spare parts costs by preventing overuse or premature replacement of wear components.
Implementation Method 1
The sensor (61) comprises at least the measuring section (64) and preferably associated electronics (measuring circuit) to detect a physical quantity of the measuring section (64) and convert it into a measurement signal dependent on that physical quantity. The measuring section (64) is designed such that the physical quantity changes with a change in the length of the wear area along the wear direction.
Implementation Method 2
by connecting at least one sensor with at least one non-contact readable electronic component for data transmission, by configuring the non-contact readable electronic component to receive measurement data from the sensor and make it available for non-contact readout
Data Source
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Figure 3
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AI summary
The invention relates to a wear component of a milling machine, a milling machine equipped with such a wear component, and a method for determining the wear of a wear component. The wear component is associated with at least one non-contact readable electronic component for determining its wear. According to the invention, at least one sensor is connected to at least one non-contact readable electronic component for data transmission, the non-contact readable electronic component is configured to receive measurement data from the sensor and make it available for non-contact readout, and at least one measuring section of the sensor extends into or along at least one wear direction to be monitored within a wear area of the wear component. The invention enables improved milling results due to optimized maintenance.