CHAIN SENSOR DEVICE AND METHOD FOR DETERMINING WEAR

Abstract

The invention relates to a method for setting up two sensor systems for monitoring the state of wear of a chain, which method comprises the steps: first positioning of the first sensor system relative to a calibration object, first positioning of the second sensor system relative to the calibration object, carrying out a first signal detection using the first sensor system, carrying out a first signal detection using the second sensor system, wherein the first signal detection using the first sensor system takes place at the same time as the first signal detection of the second sensor system.

Claims

1. A method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100), which method comprises the following steps: first positioning (2.1) of the first sensor system (201, 301) relative to a calibration object (400) first positioning (2.2) of the second sensor system (202, 302) relative to the calibration object (400) performing a first signal detection (3.1) using the first sensor system (201, 301) performing a first signal detection (3.2) using the second sensor system (202, 302) characterized in that the first signal detection (3.1) using the first sensor system (201, 301) takes place at the same time as the first signal detection (3.2) of the second sensor system (202, 302).

2. The method (1 for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that the first positioning (2.1) of the first sensor system (201, 301) and the first positioning (2.2) of the second sensor system (202, 302) take place at the same time.

3. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that a second positioning of the first (201, 301) and/or the second sensor system (202, 302) relative to the calibration object (400) takes place, the second positioning being different from the first positioning (2.1, 2.2), and/or a second signal detection takes place with the first (201, 301) and/or second sensor system (202, 302).

4. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 3 characterized in that the second positioning of the first (201, 301) and the second sensor system (202, 302) and/or the second signal detection by the first (201, 301) and the second sensor system (202, 302) takes place at the same time.

5. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that the calibration object (400) is designed in two parts.

6. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 5 characterized in that the first part (410) of the calibration object (400) is a chain (100).

7. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 5 characterized in that the second part (420) of the calibration object (400) is an element with the aid of which chain components can be positioned in relation to one another.

8. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that the method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) takes place depending on the chain type for which the sensor (the sensor systems) (201, 202, 301, 302) should be used.

9. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 8 characterized in that the chain type is a standard chain.

10. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 8 characterized in that the chain type is a standard chain according to British Standard or ANSI Standard.

11. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that the method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) takes place depending on the chain type for which the sensor (the sensor systems) (201, 202, 301, 302) should be used.

12. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 11 characterized in that the pitch of the chain (100) corresponds to 12.700 mm, 15.875 mm, 19.050 mm, 25.400 mm, 31.750 mm, 38.100 mm, 44.450 mm or 50.800 mm.

13. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 1 characterized in that the first sensor system (201, 301) and/or the second sensor system (202, 302) are suitable for detecting the position of a chain component.

14. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 13 characterized in that the first (201, 301) and/or the second sensor system (202, 302) are suitable for detecting the signals of a chain component to determine the position of the chain component over a path length range of the chain (100), for which the sensor system (200, 300) is provided.

15. The method (1) for setting up two sensor systems (201, 202, 301, 302) for monitoring the state of wear of a chain (100) according to claim 14 characterized in that the path length range is greater than or equal to ½ the pitch (p.sub.0) of the chain (100), preferably greater than or equal to ¾ the pitch (p.sub.0) of the chain (100) and more preferably greater than or equal to the pitch (p.sub.0) of the chain (100) for which the sensor system (201, 202, 301, 302) is provided.

16. A sensor device (200, 300) for determining states of wear of a chain (100) with a first sensor system (201, 301) and a second sensor system (202, 302), wherein the sensor device (200, 300) is set up for a standard chain and/or a standard pitch.

17. The sensor device (200, 300) of claim 16 for determining states of wear of a chain (100) characterized in that the chain type is a standard chain according to British Standard or ANSI Standard.

18. The sensor device (200, 300) for determining states of wear of a chain (100) according to claim 16 characterized in that the pitch (p.sub.0) of the chain (100) corresponds to 12.700 mm, 15.875 mm, 19.050 mm, 25.400 mm, 31.750 mm, 38.100 mm, 44.450 mm or 50.800 mm.

19. The sensor device (200, 300) for determining states of wear of a chain (100) according to claim 16 characterized in that the first sensor system (201, 301) is suitable for determining the position of a first chain component exclusively from the measured values detected by the first sensor system (201, 301) and/or the second sensor system (202, 302) is suitable for determining the position of a second chain component exclusively from the values measured by the second sensor system (202, 302).

20. The sensor device (200, 300) for determining states of wear of a chain (100) according to claim 19 characterized in that the sensor device (200, 300) is suitable for simultaneously detecting the measured values for determining the position of the first chain component and the position of the second chain component.

21. The sensor device (200, 300) for determining elongations of segments (13) of a chain (100) according to claim 14 characterized in that the first sensor (201, 301) and/or the second sensor (202, 302) are suitable for detecting the measured values for determining the position of the first or second chain component over a path length range of the chain (100).

22. The sensor device (200, 300) for determining elongations of segments (13) of a chain (100) according to claim 16 characterized in that the path length range is greater than or equal to ½ segment length.

23. The sensor device (200, 300) for determining elongations of segments (13) of a chain (100) according to claim 16 characterized in that the segment length corresponds to the distance between the first chain component and the directly adjacent second chain component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Exemplary embodiments of the method according to the invention for setting up two sensor systems for monitoring the state of wear of a chain and of the sensor device according to the invention are shown in a schematically simplified way in the drawings and are explained in more detail in the following description.

[0044] In the drawings:

[0045] FIG. 1 shows a sensor device according to the invention

[0046] FIG. 2a is a side view of the first part of the calibration object according to the invention

[0047] FIG. 2b is a side view of the second part of the calibration object according to the invention

[0048] FIG. 2c is a plan view of the first part of the calibration object according to the invention

[0049] FIG. 3 shows a calibration object according to the invention arranged ready for use

[0050] FIG. 4 shows another embodiment of the sensor device according to the invention with a common decentralized control

[0051] FIG. 5 shows the method according to the invention

[0052] FIG. 6 shows another example of the method according to the invention

[0053] FIG. 7 shows the dimensions of a standardized chain according to the NASI Standard or the British Standard

DETAILED DESCRIPTION

[0054] FIG. 1 shows the sensor device 200 according to the invention for determining the elongation of segments of a chain 100. In this and the following exemplary embodiments, the chain 100 to be monitored is designed as a one-piece roller chain and has alternating inner 110 and outer side parts 120 which are connected to one another by chain link pins 140 guided in chain bushings 130. When the chain 100 is new, the chain pins 140 are at a distance p0 from one another.

[0055] The length L0 of the chain 100 in new condition between the sensors 201, 202 is an integer multiple of the distance p0 between two adjacent chain pins 140 (L0=n*p0). Each sensor system 201, 202 has a respective sensor 211, 212, which is designed as a differential transformer in this and the following exemplary embodiments. In addition, each sensor system 201, 202 has a control 221, 222. The sensor systems 201, 202 together with the electrical connections are arranged in a housing (not shown) for protection against dirt.

[0056] To determine the elongation of chain 100 during operation, the sensor device 200 is positioned perpendicular to the joint axis of the chain 100 to be monitored in such a way that when the chain 100 is new, the distance D between sensor systems 201, 202 corresponds to an integer multiple of distances p0 between two adjacent chain pins 140 of the chain 100 to be monitored. Method 1 according to the invention for setting up two sensor systems 201, 202 is carried out for performing the precise calibration of the positioning of the sensor systems 201, 202 at the stated correct distance D from one another (see FIGS. 5, 6).

[0057] For this purpose, a first positioning 2 of the first sensor system 201 and a first positioning 3 of the second sensor system 202 in relation to the calibration object 400 are performed. A first signal detection is then carried out using the first sensor system 201 4, and at the same time a first signal detection 5 using the second sensor system 202 takes place. The method according to the invention provides a reproducible distance D between the sensor systems 201, 202.

[0058] The sensors 211, 212 are composed of a primary coil and two secondary coils and therefore have three sensor elements. Each of the differential transformers 211, 212 is thus suitable for simultaneously recording measured values over a length range of the chain 100 to be monitored. The length of the length range in the direction of the chain movement is based on the length p, p0 of a chain link of the chain 100 to be monitored and equals p0 in this exemplary embodiment. The detection of the measured values by the two differential transformers 211, 212 also takes place simultaneously.

[0059] The calibration object 400, which is used in the method 1 according to the invention, is shown in FIGS. 2 and 3. The calibration object 400 has two parts 410, 420: the first part 410 is the actual chain 100 to be monitored (FIG. 2b, c) or a chain section of a chain type of the chain 100 to be monitored. The chain 100 is a one-piece sleeve-type chain as described in FIG. 1. Alternatively, a roller chain can also be used. Such a chain 100 to be monitored is a standard chain according to ANSI Standard of the American type (DIN 8187) or according to British Standard (BS, DIN 8188). The chains according to these standards do not differ in the respective pitches p0. The chains according to ANSI Standard or British Standard differ in other dimensions (see FIG. 7), for example in the length of the chain pins.

[0060] The second part of the calibration object 400 is a template 420 (FIG. 2a) which has recesses 421 and serrations 422. The recesses 421 in the form of a semicircle or a segment of a circle have a center distance from one another which corresponds to the pitch p0 of the chain type whose elongation AL is to be monitored by the sensor device 200. The diameter of the recesses 421 also corresponds to the diameter of the chain bushings d of the chain type whose elongation AL is to be monitored with the sensor device 200.

[0061] The chain 100 for carrying out the method 1 according to the invention for setting up two sensor systems 201, 202 is arranged ready for use (FIG. 3) on the template 420 in such a way that the chain bushings 130 are arranged in the recesses 421. The sensor systems 201, 202 are then positioned in such a way that the distance D between the sensor systems 201, 202 corresponds exactly to an integer multiple of the distances p0 between two adjacent chain pins 140 of the chain 100 to be monitored. In the case of a roller chain, the rollers are positioned in the template 420 and the corresponding roller dimensions for the template 420 are used.

[0062] An exemplary, incomplete listing with the dimensions according to FIG. 7 of different one-piece roller chains according to ANSI Standard of the American type (DIN 8187) or according to British Standard (BS, DIN 8188) is shown in the following table. Method 1 according to the invention can be used for all of these chain types. However, the second part 420 of the calibration object 400 must be selected accordingly for each chain type according to the pitch p0 and the diameter d of the chain bushings 130.

TABLE-US-00001 Roller Plate Joint Pitch × DIN Pitch Inside Outside diameter height area Weight inner ISO p.sub.0 b a d g f q width number (mm) (mm) (mm) (mm) (mm) (cm.sup.2) kg/m ½ × 5/16″ 08B-1 12.7 7.75 16.9 8.51 12.2 0.5 0.7 ½ × 8/16″ ANSI 40 08A-1 12.7 7.94 16.6 7.95 12 0.44 0.6 ⅝ × ⅜″ 10B-1 15.875 9.65 19.5 10.16 14.4 0.67 0.95 ⅝ × ⅜″ ANSI 50 10A-1 15.875 9.53 20.4 10.16 14.4 0.7 1 ¾ × 7/16″ 12B-1 19.05 11.75 22.7 12.07 16.4 0.89 1.25 ¾ × ½″ ANSI 60 12A-1 19.05 12.7 25.3 11.91 18 1.06 1.47 1″ × 17 mm 16B-1 25.4 17.02 36.1 15.88 21.1 2.1 2.7 1 × ⅝″ ANSI 80 16A-1 25.4 15.88 32.1 15.88 22.8 1.79 2.57 British Standard - DIN 8187; ANSI Standard - DIN 8188 Min. and max. dimensions for the chains are specified in the respective standards.
The table above shows concrete nominal dimensions as an example

[0063] FIG. 4 shows a further exemplary embodiment of setting up a sensor device 300 according to the invention for determining the elongation of segments of a chain 100. The sensor device 300 has two sensor systems 301, 302 connected by an evaluation circuit 330. The sensor systems 301, 302 are positioned using method 1 according to the invention such that when the chain 100 is new, the distance D between the sensor systems 301, 302 corresponds exactly to an integer multiple of the distances p0 between two adjacent chain pins 140 of the chain 100 to be monitored.

[0064] The sensor systems 301, 302 can be designed as inductively operating differential transformers, with which the position of chain components is determined. Such sensor systems 301, 302 detect chain components—in this exemplary embodiment the chain bushings 140—over a length range of the sensors 311, 312.

[0065] The symmetry of the sensors 311, 312 is disturbed by the passage of the chain component 140. The asymmetry created by the chain component 140 is greatest when the chain component 140 is arranged in the region of the sensors 311, 312 at the edges of the sensors 311, 312, i.e. is moved out of or into the sensor region. The sensors 311, 312 then generate a maximum output voltage U when the chain component 130 is positioned at the edge of the sensors 311, 312. The asymmetry and the resulting output voltage generated by the sensors 311, 312 is U=0 when the chain component 140 is positioned in the middle of the sensors 311, 312. The length value is determined via the pitch (distance between two adjacent chain links of the chain). The length value, like the distance between the chain components, is continuously and simultaneously determined.

[0066] The sensor system 301 generates the positions via the trigonometric functions Asin and Acos, the sensor system 302 generates the positions via the trigonometric functions Bsin and Bcos. The elongation ΔL of the chain 100 then results from the position differences, which are calculated from the two sensor systems 301, 302:

ΔL/L0=(arctan (Bsin/Bcos)−arctan (Asin/Acos))/D

[0067] However, the sensor systems 301, 302 can also be optical or magnetic sensors or a combination of the types of sensors mentioned. The sensor systems 301, 302 are each connected to an evaluation circuit 330. The controls 321, 322 supply the detected measured values to an evaluation circuit 330, in which the analog measured values are converted into digital values and stored on the microcontroller. In this exemplary embodiment, a permanent magnet 340 is arranged on chain 100, the position of which is detected by means of a Hall sensor 350 and the evaluation circuits 330. The microcontroller of the evaluation circuit 330, which is connected to the Hall sensor 350, registers the position of the permanent magnet 340 and enables the individual chain links to be identified by continuously counting the passages of the permanent magnet 340 on the sensor systems 301, 302.

[0068] An exemplary embodiment of method 1 according to the invention for setting up two sensor systems for monitoring the state of wear of a chain 100 is shown in FIG. 5. For this purpose, a first positioning 2.1 of the first sensor system 201 as well as a first positioning 2.2 of the second sensor system 202 relative to the calibration object 300 are performed. A first signal detection 3.1 is then carried out using the first sensor system 201, and at the same time a first signal detection 3.2 is carried out using the second sensor system 202. This is followed by a separate evaluation 4.1, 4.2 for each sensor system 201, 202 of the measured values determined by the first sensor system 201 and second sensor system 202 with regard to whether the two sensor systems 201, 202 simultaneously detect a chain component 130. The method 1 according to the invention provides a reproducible distance D between the sensor systems 201, 202. In this context is important at which position in the sensor region the chain components 130 are located—this is how the sensor learns the correct distances p0 and compensates for the individual production-related deviations. The method 1 according to the invention is advantageously carried out several times in succession in order to detect and compensate for any fault states due to different chain geometries over the chain length and due to mechanical and metrological tolerances.

[0069] FIG. 6 shows a variant of the method 1 according to the invention for setting up two sensor systems for monitoring the state of wear of a chain 100. For this purpose, a first positioning 2.1 of the first sensor system 201 and a first positioning 2.2 of the second sensor system 202 in relation to the calibration object 400 are performed. A first signal detection 3.1 is then carried out using the first sensor system 201, and at the same time a first signal detection 3.2 is carried out using the second sensor system 202. This is followed by an evaluation 4 of the measured values determined by the first sensor system 201 and second sensor system with regard to whether the two sensor systems 201, 202 simultaneously detect a chain component 130. Method 1 is also carried out several times.

LIST OF REFERENCE NUMERALS

[0070] 1 method forsetting up two sensor systems to monitor the state of wear of a chain

[0071] 2.1 first positioning of the first sensor system

[0072] 2.2 first positioning of the second sensor system

[0073] 3.1 first signal detection using the first sensor system

[0074] 3.2 first signal detection using the second sensor system

[0075] 4, 4.1, 4.2 evaluation

[0076] 100 chain

[0077] 110 chain inner link

[0078] 120 chain outer link

[0079] 130 chain bushing

[0080] 140 chain pin

[0081] 200 sensor device

[0082] 201 first sensor system

[0083] 202 second sensor system

[0084] 211, 212 sensor

[0085] 221, 222 control

[0086] 300 sensor device

[0087] 301 first sensor system

[0088] 302 second sensor system

[0089] 311, 312 sensor

[0090] 321, 322 control

[0091] 330 evaluation circuit

[0092] 340 permanent magnet

[0093] 350 Hall sensor

[0094] 400 calibration object

[0095] 410 first part of the calibration object/chain

[0096] 420 second part of the calibration object/measuring template

[0097] 421 recess

[0098] 422 serration

[0099] d roller diameter

[0100] p0 pitch (distance between two adjacent chain pins) in new condition

[0101] p pitch (distance between two adjacent chain pins) in actual condition

[0102] L0 length of chain between first and second sensor system, new condition

[0103] L length of chain between first and second sensor system, actual condition

[0104] ΔL elongation of the chain

[0105] D distance from 1st sensor system to 2nd sensor system