Wear Part Measuring Device with Resistance and Vibration Sensors
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Solution Overview
Problem
Existing devices for detecting mechanical material removal on wear surfaces lack a comprehensive and objective method to predict the service life of wear parts, leading to inconsistent wear measurement and comparison across different copper plates.
Innovation Solution
A device equipped with a vibration sensor and an electrical resistance sensor integrated into the wear surface, which records changes in ohmic resistance to measure material removal, allowing for the determination of service life based on vibration amplitude and frequency thresholds, and enabling continuous, automated wear detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measuring devices are used to detect material removal on wear surfaces, then wear detection is possible, but the operating time of wear parts cannot be accurately recorded and wear data cannot be uniformly compared across different copper plates
Solution Approach 1:
The patent introduces an electrical resistance sensor as an intermediary element that is integrated into the wear surface. This sensor acts as a mediator that converts mechanical wear (material removal) into electrical resistance changes, which can be precisely measured and correlated with operating time. The intermediary sensor enables accurate wear detection while simultaneously providing data for reliable service life prediction.
Solution Approach 2:
The patent utilizes parameter changes by monitoring the electrical resistance value, which changes as material is removed from the wear surface. The resistance change serves as a direct indicator of wear progression. Additionally, the system uses vibration amplitude and frequency as dynamic parameters to determine operating time, creating a comprehensive measurement approach that improves both measurement precision and reliability.
2Productivity
If wear detection is performed without integrated sensors, then device complexity is reduced, but continuous automated monitoring and real-time wear data are not available
Solution Approach 1:
The patent merges the wear sensing function directly into the wear surface by integrating an electrical resistance sensor within the copper plate structure. This combination eliminates the need for separate external measuring devices and enables continuous automated monitoring. The evaluation device is also integrated to process resistance changes and vibration data, creating a unified system that provides real-time wear information without requiring complex external equipment.
Solution Approach 2:
The wear detection system performs self-service by using the wear surface itself as part of the sensing mechanism. The electrical resistance sensor is embedded in the wear surface, so the wear process directly affects the sensor's measurement parameter (resistance). This self-integrated approach enables automated monitoring while minimizing additional device complexity, as the structure being monitored becomes part of the monitoring system.
3Measurement precision
If multiple sensors are integrated into the wear surface, then wear detection precision and operating time recording are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements multi-functionality by using a single integrated evaluation device that processes multiple types of sensor data (electrical resistance changes and vibration signals) to perform various measurement functions. The evaluation device determines both wear amount from resistance changes and operating time from vibration analysis, eliminating the need for separate dedicated devices for each measurement type. This universal approach improves measurement precision while simplifying the manufacturing process compared to implementing multiple separate sensor systems.
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 provides timely, uniform, and comparable wear data, enabling objective quality comparison and accurate prediction of remaining service life, allowing for optimized maintenance and production planning.
Implementation Method 1
a wear sensor in the form of an electrical resistance (122), which is integrated into the wear surface (112) and is itself mechanically worn away when material is removed from the wear surface (112); an evaluation device (124) for detecting a change, in particular an increase, in the ohmic resistance value of the electrical resistor (122) as a function of its own material removal
Implementation Method 2
a vibration sensor (126) for detecting whether the wear part (110) is set into vibration; and that the evaluation device (124) is configured to determine the operating time of the wear part (110) as the period during which the amplitude or frequency of the vibration of the wear part (110) exceeds a predetermined threshold value
Data Source
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Figure 3~4
AI summary
The invention relates to a device comprising a wear part and a measuring device for detecting mechanical material removal from a wear surface of the wear part. Furthermore, the invention relates to a method for operating such a device. According to the invention, the measuring device has a wear sensor 122 in the form of an electrical resistor, which is itself mechanically worn away during the material removal from the wear surface. The measuring device also has an evaluation unit for detecting a change in the ohmic resistance value of the electrical resistor as a function of its own material removal and for deducing from the detected change in resistance value the extent of material removal from the wear surface 112 or the remaining thickness of the wear surface.The device and method according to the invention are characterized in that the measuring device 120 further comprises a vibration sensor 126 for detecting whether the wear part is set into vibration; and that the evaluation device 124 is designed to determine the operating time of the wear part 110 as the period of time during which the amplitude or frequency of the vibration of the wear part exceeds a predetermined threshold value.