DE102008018238A1 - Apparatus and method for non-destructive monitoring of the operating state of components made of elastomers - Google Patents

Abstract

The invention relates to a device for nondestructive detection of an operating state of elastic components (9), in particular conveyor belts, conveyor belts or belts with an elastic member (9), which has a band-like shape and in a band circumferential direction at least a first measuring range (3) and at least one second measuring range (1), wherein the first measuring range (3) has a faster over time at least decreasing tensile strength than the second measuring range (1) and in the measuring ranges (1, 3) of the elastic member Elastomerencoder (8, 8 ') embedded are, a sensor station (15), with the of the Elastomerencoder (8, 8 ') outgoing magnetic fields when passing the sensor station (15) are detectable and unchangeable in output signals, and a process unit (16) of the sensor unit (15) receives transmitted signals, processed to strain data, and thus a first elongation of the elastomeric encoder (8) extending into a In the first measuring range are located and a second elongation of Elastomerencoder (8 ') which are located in a second measuring range of the elastic member determined.

Description

The The invention relates to a device and a method for non-destructive In-situ monitoring of the operating status of components made of plastics, in particular elastomeric materials (rubber), the components preferably as quasi-endless belts, straps or bands can be formed and different engineer technical functions (eg power transmission, Transport of bulk goods, etc.). Also conceivable are elastomeric components that during their use of a Shear, bending, tensile and / or compressive load are exposed, wherein this cause a deformation of the components.

elastomers possess due to their macromolecular structure (high polymers) and a wide-meshed networking of their molecular chains very specific, different from the metallic materials Stress / strain mechanism. They show, for example thermodynamically entropy-elastic behavior, d. H. that at a deformation under Elongation of the clogged chain molecules of the statistically probable arrangement state of this decreases, however, a higher one Order state is reached (unlikely state with decreasing Entropy). After deformation, the macromolecules endeavor to the initial state of ideal statistical disorder with maximum To take entropy again. Polymer materials such as elastomers are viscoelastic substances, d. H. that the deformation process both characterized by elastic as well as viscous deformations is.

at purely elastic deformation is the stored energy after the Relief released again, viscous deformations, however, cause a Transformation of the deformation energy into heat. These viscous Shares cause a strong time, temperature, frequency and amplitude dependence the material characterizing the deformation.

ever After loading of the components, these dependencies are made clearly in different material effects. Elastomers show under defined Loads, whether static, quasi-static or dynamically applied, Phenomena of the decrease in tension at constant deformation (relaxation) or a strain increase at constant stress (flow or creeping; Retardation), d. H. that with repeated deformation an ever-increasing way to complete is to to achieve the same power. Make dynamic demands also in voltage softening or frequency- and / or amplitude-dependent Module deviations noticeable. These special laws It is important to note if the operating behavior of elastomeric Components monitored under practical conditions shall be.

on the other hand this characteristic material behavior also offers the possibility Deviations of the typical for each component stress / deformation behavior record and normal states with different states to compare. The definition of deviation or achievement of a so-called damage limit sets the knowledge of the operating conditions as material and component-appropriate, d. H. normal process ahead. There are continuum mechanics as well as first Line bruchmechanische regularities to note.

A Establish fatigue life or service life prognosis sets Many years of operating experience and a subject-specific Know-how of both the component supplier and the plant operator ahead and is the task of the technical staff z. B. one Belt conveyor, which with the operation, care, Maintenance and servicing is entrusted. Belt conveyors are essential technical aids for extraction and transport of bulk materials. You will u. a. in the coal, Mineral and mineral industries are used and found both in the mine underground as well as in open pit mining over days one always increasing use. In addition to the construction the conveyor systems as well as their most important machine elements such as drives, clutches, brakes, carrying-drive, deflection, tension and buckling rolls or drums belongs to the recording the bulk goods provided conveyor belt to the plant components, which are in the special interest of all maintenance efforts because they are in direct contact with the often highly abrasive Bulk goods are and thus exposed to special wear are.

ever conveyor technology demands conveyor belts as steel cable, textile or aramid fiber conveyor belts for Commitment. For the purpose of reinforcing the elastomeric material component with the objective of ensuring and maintaining the highest Material strength values and the fulfillment of maximized Operating requirements for the longest possible Operation duration are those with steel cables, textiles or Fibers provided so that they in the main stress (transport) direction highest resistance to oppose in the Location are.

Conveyor belts are system-specific designed so that they can complete an endless circulation along the projected conveyor or transport route. The endless closure is realized in that two end pieces by means of special Ver binding procedures are connected. This technique is also used to partially renew the conveyor belt by replacing worn sections with new parts or regenerated belt segments.

There in this case the direct connection of the reinforcing materials broken or weakened, deserves this connection section special attention in operational fatigue inspections. By special overlapping techniques of reinforcing elements is achieved that the transmission or belt force into the other element to be connected, where the interposed elastomeric material is subjected to shear becomes. Thus, the long-term stress-strain behavior of the involved elastomer layers for achieving a high level of operational stability or Life of the conveyor belts decisive. This is true also too, if by damaging the reinforcing layers (Crack, punch, break) whose effect is canceled or restricted is and the elastomeric layers increased stresses are exposed. It does not take that for granted in the past Many attempts have been made through a variety of monitoring techniques the failure of the conveyor belt, but in particular the Predetermining connection as one of the critical component regions and thus a major accident or plant shutdown with far-reaching to avoid negative economic and business consequences.

Next the usually highly subjectively influenced manual Controls on said conveyor systems, consisting of various business reasons not permanently to ensure are, in particular, technical solutions enforced, the more and more new findings of electronics, sensors and use data processing. The advantage is that as a result the band observations opened the possibility has the typical damage patterns and phenomena statistically and in the form of a causal cause-and-effect relationship display. It must distinguish between damage caused by material or manufacturing defects a priori conditionally or process-dependent initiated or a posteriori as a result of overloads occur.

Due to the process are cover plate damage (punctures, cracks) the conveyor belt, in particular on the support and running side through wear (wear wear), abrasion (abrasion wear), Rubbing (adhesive wear), erosion (erosional wear) and fatigue (fatigue wear) and their combinations (combined wear) as a reduction or havarieähnliche disorders. This also applies to so-called edge damage to. Replacement of material layers often has its cause in materials and production or assembly-related processes and always lead to weakening of the belt material and / or the connection. This concerns primarily a weakening the connection between newly applied (connecting) material and the reinforcing material (carcass) bonded to elastomers. These damages are highest in the area Stress concentration, d. h thus directly on both sides before or directly in the contact zone, made of bonding and base material is formed or in the zones where the cable ends of both sides of the connection stand unbound.

The Loading the actual connection length is due the shear stress transmission of the coupling elastomer with the train carriers relatively manageable and in the Compared to the contact zone more stable, but without the strength level to reach the original belt material.

The publication US 4,020,945 describes a method in which by attaching markers at the beginning and end of the connection, a change in length between the markings can be detected by means of sensory detection. Permanent pulses triggered by permanent magnets define a "critical strain" as the beginning of the damage.

Likewise, using RFID (transponder) technology is in the DE 196 03 578 a monitoring method is shown, which operates on the principle that introduced by an increased unacceptable load in a conveyor belt transponder integrated into integrated circuits are no longer able to send signals to the arranged on the conveyor system transmitting and receiving station.

Magnetic induction Allow tests on conveyor belts an insight into the interior of a suspected damaged Section. An interpretation is difficult and must then by a additional X-ray technology are supported.

The use of high energy (X-ray) is in the DE 10 2004 061 367 mentioned. After irradiation of the belt, a process computer evaluates the result obtained. The assignment to the damaged area is made with the help of markings (magnets, encoders).

A similar solution is in the DE 2004 00 1899 ( WO 2005/023688 ) to find. With the help of optoelectronic systems and subsequent evaluation by a process computer, it is possible to monitor the belt surface over a large area. The conveyor belt and thus the connection is divided into finite sections, which are characterized by start marks in the form be limited by coupled with a process computer encoders.

In the belt or the connection incorporated so-called conductor loops US 4854446 are mentioned inductively coupled in the injury due to high Gurtbeanspruchung cause a change in the measurement signal.

Out The illustrated operating experience is to conclude that Further developments of the technique of magnetic measuring marks determined changes in length of the compounds in terms of reliability and reduced susceptibility in Attack should be taken. As a damage criterion is a Increase of the connection length (7 m long) of 1 ‰, since this is already a doubling of the scattering range of 3 mm.

newer Investigations to determine and calculate the component strength or lifetime of elastomeric materials and for refinement the testing technique using new dynamic crack growth studies (Tear Fatigue Analyzer Test (TFA)) incorporating continuum and fracture mechanics material approaches allow the To describe the failure behavior of elastomers more precisely and to better evaluate the progress of the damage. In tension-determined Processes such as in a belt conveyor are of interest here the deformation-related characteristics. After that it is necessary to a clearer determination or metrologically reliable Detection of a material damage beginning to arrive in a component, in particular the zones of critical deformations and high-resolution stresses to detect to define different areas of damage history to be able to.

All Previously known methods and methods have the disadvantage that they are the sometimes very narrow zones of Bruchimitiierung and the Crack growth on the component as the starting point of the failure is not precise capture and thus relatively unreliable values for provide the life expectancy. However, these are required to make a decision that in a certain stage of failure at least partially repair or replace existing component are. Another difficulty is to be seen in the fact that the assignment to the place of damage, d. H. the identification with two different systems is realized which additional Error source includes.

The The object of the invention is therefore a method, a device and a locally high-resolution non-destructive measurement system the operating state of elastic components, in particular of Conveyor belts, conveyor belts or belts, specify the statically and / or dynamically loaded components in situ safe and reliable monitoring.

About that In addition, the measuring system should be able to determine the measuring location exactly as Identify integrated measuring task without separate additional measuring systems or localize and as a result of the particular Arrangement of the measuring points is an additional possibility opened, a number of other monitoring functions to take over (eg belt misalignment, wear). Furthermore, an evaluation method should be provided with whose help it is possible, critical component states safe to capture.

The Task is by the independent claims solved. The dependent claims relate to advantageous developments of the invention.

The device for nondestructive detection of an operating state of elastic components, in particular conveyor belts, conveyor belts or belts may have at least one elastic component which has a band-shaped configuration and has at least one first measuring range and / or at least one second measuring range in a band-circumferential direction of the elastic member elastomerecoder can be embedded. Furthermore, a sensor station can be provided, with which magnetic fields emanating from the elastomer encoders can be detected as they pass through the sensor station and can be converted into output signals. Furthermore, a process unit can be provided which receives signals transmitted by the sensor unit, processes them into strain data, and thus a first elongation of the elastomere encoders located in a first measuring range and / or a second elongation of the elastomere encoders located in a second measuring range of the elastic component. In this case, the process unit can determine a first strain difference between the first strain and a first predetermined strain value and / or determine a second strain difference between the first strain and the second strain and / or determine an operating state of the elastic component based on the determined strain difference. This results in the advantage that for detecting the operating state and thus for monitoring the wear, the belt conveyor does not have to be stopped or dismantled. Thus, the conveyor can be kept permanently in operation whereby the service life is reduced. In addition, the number of components is reduced since the same encoders are used to detect the conveyor belt speed and belt wear. Through the reference measurement in the second measurement can be poor measurements due to environmental influences, such as temperature, pressure and humidity are prevented.

there may be the first predetermined elongation value of a maximum allowable Elongation of the component to be examined correspond. This value can be stored in a memory or a database. Database may be in the form of a table with elongation values, each according to material, age, environmental conditions of the component, vary. According to these criteria, a first strain value is calculated from the Table predetermined. The first and the second strain difference are compared with a first and second value, respectively. This first or second value corresponds to a maximum permissible expansion difference of the component to be examined. These values can be in one Memory or a database stored. The database can be a Have a table of strain differential values, which vary depending on the material, Age, environmental conditions of the component, may vary. According to these criteria becomes a first or second value from the table.

Farther For example, the first measuring range may be an area in which two ends of the elastic member are connected together. Furthermore, the first measuring range one at least faster over time have decreasing tensile strength as the second measuring range.

Farther can the process unit if the determined first strain difference exceeds a first predetermined value or the determined second strain difference exceeds a second predetermined value, at least output a predetermined operating condition signal.

Farther the operating state signal can be a current strain state or correspond to a strain state in which the first strain difference exceeds the first predetermined value or the second Elongation difference exceeds the second predetermined value.

Farther can detect detectable with the sensor station magnetic Fields have alternating polarity, the stretching of the elastic component simultaneously with the rotational speed be determined of the elastic member, and / or a second, parallel embedded, as barcode magnetized elastomeric encoder and at least one additional sensor in the sensor station be provided, wherein with the additional Elastomerencoder a Band section can be clearly identified.

Farther For example, the device may include a sensor station having at least two analogue stations Have sensors with preamplifier and / or a local processor unit.

Farther The device may have a second, parallel embedded, as Barcode magnetized elastomeric encoder and / or at least one additional, third sensor in the sensor station, with the additional Elastomerencoder a band section is clearly identifiable.

In order to can in a particularly simple way the monitored band section be clearly identified.

Farther In the strain measurement, the device can stretch by independent measurements double determine.

Consequently An improvement of the redundancy can be achieved.

Farther can with the device locates the strain, preferably with a spatial resolution of one pole width, of a maximum of 50 mm, be determinable.

Farther can with the device locates the strain, preferably with a spatial resolution of two pole widths, of a maximum of 100 mm, be determinable.

Farther can the Elastomerencoder by adding a filler wherein the filler is strontium ferrite (SrFeO) and / or an iron alloy (NdFeB), the elastomeric encoder by adding a filler of 20 to 40 vol.% Strontium ferrite (SrFeO), but preferably 30 vol.% Strontium ferrite (SrFeO), and / or from 5 to 30 vol% iron alloy (NdFeB) modified elastomer blend can be produced and covered by non-magnetic material can be.

Farther can by adding this filler the mechanical-physical properties of Vulkanisates the Elastomerencoders only be immaterial changeable.

Farther For example, the elastomeric encoder may be a tape and / or a plate having a thickness from 1 mm to 5 mm and dimensions preferably of 1000 mm in length and 100 mm wide and / or from such bands and / or plates be composable.

Farther The elastomer encoder can be used both before installation in the elastic Component (a conveyor) as well as after its installation by means of pulse magnetization technology, when using specially modified Elastomer mixtures, be magnetizable.

Farther can the Polbreiten or Polabständen the Elastomerencoders from 20 mm to 50 mm, but preferably 40 mm.

Farther the device may be characterized in that the orientation the Elastomerencoder a maximum of 5 ° from the conveying direction or direction of travel of the conveyor deviates.

Farther The elastomer encoder can be designed with those for elastomers Joining method fastened in the conveyor can be.

Farther can be a width of Elastomerscoders to a measuring width of the sensor be so adaptable that at extreme belt misalignment of the conveyor the sensors no longer reach the measuring range of the elastomer encoder and thus an error message can be triggered.

Farther For example, the elastomeric encoder may be coded such that its mounting location can be identifiable.

Farther may be a device for conveying goods at least consist of an elastic member, which is a band-shaped Can have at least one shape and in a band rotation direction first measuring range and / or at least one second measuring range can have. It can be in the measuring ranges of the elastic Embedded component elastomeric encoder. Furthermore, a Sensor station be provided with that of the Elastomerencoder outgoing magnetic fields (pulses) when passing the sensor station detectable and unchangeable in output signals. Farther For example, a process unit may be provided by the sensor unit receives transmitted signals, processed into strain data, and thus a first elongation of the Elastomerecoder located in a located first measuring range and / or a second elongation of the Elastomerencoder which are located in a second measuring range of the elastic component, determine. Furthermore, the process unit may have a first expansion difference between the first strain and a first predetermined strain value determine and / or a second strain difference between the first strain and determine the second strain and / or based on the determined Elongation difference an operating condition of the elastic member determine.

Farther For example, the first measuring range may be an area in which two ends of the elastic member are connected together. Furthermore, the first measuring range one at least faster over time have decreasing tensile strength as the second measuring range.

Farther For example, if the determined first strain is one exceeds or first determines the predetermined value Strain difference exceeds a second predetermined value, at least output a predetermined operating condition signal.

Farther the operating state signal can be a current strain state or correspond to a strain state in which the strain is the first exceeds predetermined value or the expansion difference exceeds the second predetermined value.

Farther can at least one running side and at least one support side provided be, between the running side and the support side stretchable elastomere encoder are embedded, which are suitable alternating magnetic signals issue.

Farther For example, the elastomers encoders can be specified in a particular layout embedded, which with the arrangement of sensors of a sensor station corresponds.

Farther can across the width of the device for conveying distributed by goods, at least three elastomere encoders in the transition zones, which extend into deflection zones of Ropes or a displacement zone of cable ends can extend, and / or are in rope end clearance zones.

Farther can at least between connections of the device three reference elastomere encoder in each case in the middle and in the be arranged on the right and left edge areas.

Farther The elastomer encoders can be used in one of the measuring equipment the sensor station dependent distance from the running side, from the support side and / or from the upper and / or lower level of steel cables, depending on their rope diameter, are located.

Farther the elastomeric encoder can be used in a transition zone with a Half of its length in a strap side and anchored to the other half in a connection page be.

Farther For example, the elastomeric encoders may be in a rope end clearance zone be positioned so that they cover both ends of the rope.

Furthermore, a sensor station with which magnetic fields emanating from elastomer encoders can be detected as they pass through the sensor station and can not be converted into output signals can be provided. In this case, the elastomere encoders can be embedded in measuring areas of an elastic component which has a band-shaped form. there For example, the elastic component may have at least one first measuring range and at least one second measuring range in a band circumferential direction. Furthermore, a process unit may be provided which receives the signals emitted by the sensor unit, processed into strain data, and thus a first elongation of the elastomere encoders located in a first measurement range and / or a second elongation of the elastomere encoders located in a second measurement range of the elastic component determine. Furthermore, the process unit can determine a first strain difference between the first strain and a first predetermined strain value and / or determine a second strain difference between the first strain and the second strain and / or determine an operating state of the elastic component based on the determined strain difference

Farther For example, the first measuring range may be an area in which two ends of the elastic member are connected together. Furthermore, the first measuring range one at least faster over time have decreasing tensile strength as the second measuring range.

Farther For example, if the determined first strain is one exceeds or first determines the predetermined value Strain difference exceeds a second predetermined value, at least output a predetermined operating condition signal.

Farther the operating state signal can be a current strain state or correspond to a strain state in which the strain is the first exceeds predetermined value or the expansion difference exceeds the second predetermined value.

Farther The sensor station can be positioned on a belt conveyor depending on the head or rear drive situation, both on the running side of an upper run as well as the running and carrying side a lower strand, the belt conveyor, positionable is.

Farther Depending on the system situation, the sensor station can be close by a belt conveyor drum, a roller system and / or a Pressure roller in the form of a support or Anpresstrommel be positioned, with their distance to the running side of the conveyor belt is minimal and / or the sensor station rests directly on this.

Farther Depending on the plant situation, the sensor station can be located between a bulk material feed point and / or a bulk material transfer or bulk discharge point be mounted in the lower or upper strand on the running side.

Farther can the sensor station on the constructive normal Transport position of the conveyor so aligned be that both are equipped with Elastomerencodern Edge regions as well as a central region of the conveyor are detectable.

Farther the sensor station can optionally be traversingly movable as a single station, and / or permanently installed as a triple station, each with a single station in the peripheral areas and a single station in the central area, be arranged.

Farther For example, the sensor station may have at least two sensors with a predetermined one Include sensor distance.

Farther The sensors can Hall sensors of ratiometric linear Type are.

Farther the device may be characterized in that the sensor station connected to a process unit.

Farther can at least one connection between the sensor station and the Process unit be provided, these via cable and / or wireless is executed.

Farther can use the process unit to send data to a plant-specific Operational data collection system are forwarded, with information about any sturgeon situations are available, due to their An emergency shutdown of the system can be carried out with a system control is.

The The invention further relates to a method for nondestructive Detecting an operating state of elastic components, in particular of conveying devices and can have the following steps: Detecting a first elongation of elastomer encoders that are in a embedded first measuring range of a conveyor are, determining a first strain difference between the first Elongation and a first predetermined strain value, and / or detection a second stretch of elastomeric encoder, in a second Measuring range of the conveyor are embedded, determination a second strain difference between the first strain and the second strain, determining an operating condition of the elastic Component based on the determined strain difference, output at least one operating state signal when the determined first Strain difference exceeds a first predetermined value and / or if the determined second strain difference is a second exceeds predetermined value.

In a further step, if the determined first elongation is a first predetermined Value exceeds or the determined strain difference exceeds a second predetermined value, at least a predetermined operating condition signal are output.

The Operating state signal can be a current strain state and / or correspond to a strain state in which the strain is the first exceeds predetermined value and / or the expansion difference exceeds the second predetermined value.

Farther can by the process of elongation of the components and the conveying speed are recorded simultaneously.

Farther can be an elastomerecoders for strain measurement of elastic components be used, wherein the elongation of an elastic member based an elongation of at least one elastomerecoders can be detected.

Farther can the elongation of the elastic member simultaneously with the rotational speed of the be detected elastic component.

Farther can the Elastomerencoder by adding a filler wherein the filler is strontium ferrite (SrFeO) and / or an iron alloy (NdFeB), the elastomeric encoder by adding a filler of 20 to 40 vol.% Strontium ferrite (SrFeO), but preferably 30 vol.% Strontium ferrite (SrFeO), and / or from 5 to 30 vol% iron alloy (NdFeB) modified elastomer blend can be produced and covered by non-magnetic material becomes.

Farther can by adding this filler the mechanical-physical properties of Vulkanisates the Elastomerencoders only be immaterial changeable.

Farther For example, the elastomeric encoder may be in the form of a belt or plate having a thickness of 1 mm to 5 mm and dimensions preferably of 1000 mm in length and 10 to 100 mm wide and / or from such bands or plates be composable.

Farther can the Elastomerencoder both before installation and after the Installation by means of pulse magnetization be magnetized.

Farther can the Polbreiten or pole distances of Elastomerencoders preferably from 100% to 400% of the effective sensor distance.

Farther the orientation of the elastomere encoder can not exceed 5 ° of the conveyor device or direction of travel of the conveyor differ.

Farther The elastomer encoder can be designed with those for elastomers Joining method fastened in the conveyor be.

Farther can be a width of Elastomerscoders to a measuring width of the sensor be so adaptable, so that at extreme belt misalignment of the conveyor the sensors no longer reach the measuring range of the elastomer encoder and thus an error message can be triggered.

Farther For example, the elastomeric encoder may be coded such that its mounting location is identifiable.

Farther can the component to be monitored (conveyor), For example, a conveyor belt made of reinforced Plastics, in particular elastomers be that with Elastomerencodern is provided of magnetized elastomers (magnetic elastomer), and / or in a magnet encoder assembly during its functional condition Insert on a sensor system (sensor station, sensors) passed is, where permanently the state of deformation of the component to particular stress and deformation exposed areas (eg transition zone, transitional Zone, Seilendenabstandszone) measured and metrologically with the help a process computer is evaluated, which with the Betriebsdatenerfassungsungs- or control system of the system is connected.

in the The invention will be described below with reference to exemplary embodiments only illustrative drawings explained.

It show schematically and not restrictive:

1 : the laying scheme of a 3-stage Stahlseilfördergurtverbindung with it positioned Magnetcodern and Vergleichmessstellen,

2 a cross section through a transition zone of one side of a belt connection with transverse reinforcements and steel cable and the positioning of the magnetic encoder to the running side of the conveying device and the carrying side of the conveying device,

3 an arrangement of the measuring sensor system on the belt conveyor above the conveyor belt provided with magnetic encoders,

4A : an arrangement of the sensors in a sensor station with respect to the Elastomerencoders and coding of the encoder in the North Pole and South Pole.

4B : Sensor signals sent from the sensor station to the process unit,

5 : the increase in strain as a function of the number of load cycles at a predetermined load (load duration), and

6 : a belt conveyor.

Corresponding the description of the invention and the task is the principle of operation (Method) of the monitoring device in it, in zones highest Operating stress to determine the component deformation in order to determine its fatigue wear (fatigue wear).

According to the invention, the critical deformation is to be determined as such a change in length which, in contrast to the component-specific intrinsic extension, exceeds a certain amount under the operating load. Values of 2% to 4% depending on the belt version are mentioned in the literature. The values measured in the connection in the transition area between the belt side and the connection side 2 , Area 4 and 1 Area 4 respectively. 4 ' may take higher values, so accurate strain measurement should be performed in the range of 4% to 8% and beyond.

Under Use of transponders in conjunction with strain gages It would be necessary to strain-translating systems use. However, the determination of discrete maximum strain values not alone promising for the determination of a Damage limit, but only the determination of functional dependence the strain increase ΔD of the loading time allowed with high safety a general evaluation of the fatigue behavior.

Since the application of the strain gage sensors reaches certain limits, it is inventively provided to detect the fields of a special magnetic encoder via a time measurement with a sensor system. This is designed so that it reproduces the component elongation to 100%. Therefore, so-called magnetic elastomers are used, which consist of a magnetizable elastomer mixture. These elastomer blends contain a certain amount of ferritic particles (filler) which ideally align with the mixing and processing process typical of elastomer production. With the aid of a special magnetizing device, it is now possible to magnetically encode this mixture thus prepared in the form of precisely positioned north / south poles with defined pole widths and spacings. This magnetic elastomer can be in the form of a stretchable about 1-3 mm thick Magnetcoders as elastomerecoder 8th respectively. 8th' be understood.

The possible variants of the introduction of the encoder are in 1 shown. The elastic member is in the form of a conveyor belt 9 shown. To recognize the two end pieces of a connection 1 and 2 and the open for the connection, ie freed of old rubber connection length 3 , The positioning of the elastomere encoder 8th respectively. 8th' flows according to a predetermined scheme both for reference measurement in at least one second measuring range (reference ranges) on the two belt ends to be connected (in the belt side 1 see. 2 ) as well as for the strain measurement in at least one measuring range (range of critical strain) in the connection itself (connection side 3 see. 2 ). In the process, the elastomers are coded 8th' between the compounds preferably in the lateral edge regions and in the middle of the conveyor belt 9 embedded. For reference measurements, moreover, in the first measuring range (the zones of critical loads), so-called transition zones, 4 . 4 ' . 5 . 6 and 7 optionally elastomeric encoder 8th accommodate.

The introduction is usefully possible in connection, repair, regeneration in the workshop as well as on site with the known methods of joining or joining technology for elastomers possible. The width of the elastomere encoder 8th . 8th' is to be chosen so that at usual running inaccuracies of the conveyor belt 9 a measurement is still feasible.

2 shows a cross section through a contact zone of the belt side 1 and the connection side 3 a cross-armored Stahlseilfördergurtes 9 with the possible height arrangement of Elastomerecoder 8th in relation to the belt side 14 and belt carrying side 13 ,

The distance between the running side 14 as well as the possible cross reinforcements 17 and the steel cable 18 of the conveyor belt 9 is geared to both magnetic-sensitive (up to 24 mm) and wear-technical criteria. It can be seen immediately that if the elastomeric layer is the running side 14 As far as wear should reduce that the encoder 8th the abrasion are revealed, this no signals to the sensor station 15 can send out further and thus an additional wear monitoring of the running side 14 given is. This arrangement is also on the support side 13 of course conceivable. An impairment of Elastomerecoder 8th or the sensor station 15 through the crossarms 17 and steel cables 18 is to be excluded.

3 shows one of the possible arrangements of the sensor system 15 on a belt conveyor near a drive or tail pulley 10 , The with elastomer encoders 8th doped conveyor belt 9 is through or through different cleaning systems 19 led and by means of a usually so arranged buckling drum 11 with a support or Anpresstrommel 12 fixed.

The positioning of the sensor 15 is with the Elastomerencoderbreite 8th respectively. 8th' vote. Deviations during belt misalignment result in false signals. With the help of this lack of signaling, the belt misalignment can ideally also be monitored. The distance of the sensor 15 to the belt side 14 is to be chosen so that a direct contact or a metrologically still feasible distance is made possible.

The arrow R shows the direction of rotation of the conveyor belt 9 at. Of course, the functionality of the detection device is also given in the opposite direction of movement.

The sensor station 15 is with a process computer 16 connected for the purpose of measured value acquisition and measured value evaluation.

4A illustrates the measuring principle of the active Magnetcoders in the form of the described elastic Elastomerscoders 8th respectively. 8th' , With the arrangement of two magnetic sensors S1 and S2, the magnetic encoder speeds (+/- 1% with a standard deviation of 0.3%) as well as the strains (+/- 1%) can be calculated with high precision in one measurement cycle and with the Measurements on a reference measuring point located next to the connection or between the connections 8th' to compare. An encoded elastomeric encoder 8th , is passed to two sensors S1 and S2, which thereby detect magnetic north south pulses of elastomerecoders.

• I) schnell, ungedehnt
• II) langsam, ungedehnt
• III) langsam, gedehnt und
• IV) schnell, gedehnt

In the 4B the measurement signals emanating from the sensor station are shown schematically. The four combinations demonstrate the measuring principle used in the stages:

• I) fast, unstretched
• II) slow, unstretched
• III) slow, stretched and
• IV) fast, stretched

Reference measurements between the encoders 8th and 8th' are also possible according to this system. In this case, A corresponds to the signal duration of a reference signal of an encoder 8th' with which the rotational speed of the conveyor belt can be detected at a position uncritical with respect to the elongation. B is the duration of a signal from an encoder 8th which is located at a stretch-critical point in a connection point of the conveyor belt. By means of the signals A and B, an adjustment of the rotational speeds can take place and thus the presence of an elongation can be detected.

For the purpose of Integration into a computerized operating data acquisition system it is intended, the process computer via a bus system To connect with the maintenance portal and in the context of the overall system monitoring Data for evaluation for the control center for the purpose of possibly Necessary, in emergency situations indispensable plant closures to deliver. In conjunction with other measured variables This operating case can be controlled redundantly so that faulty circuits by possible measurement errors can be excluded.

Via a separate coding of the elastomere coder 8th is achieved that an accurate positioning of the damage is detectable. If required for further additional identification and information messages, it is quite possible to provide the use of transponders.

Of course, elastomere coders can be used 8th also in the intermediate layers of textile conveyor belts in single or multi-level connections or in the transition zones 4 . 4 ' apply between the two ends of the layer. This also applies to any other type of conveyor belts and conveyor belts 9 , Drive belt or the like too.

As already stated in the description and the task, it may be useful to make the determination of a damage limit based on reference strain data such as a measured relationship strain increase = f (load cycle number, load duration), wherein the strains on the encoders 8th measured and with the strain in remote connection encoder 8th' is compared.

In 5 Such an association is exemplified when testing an elastomeric component. The graphs in the left half show component fatigue based on strain versus load cycles, and the graphs in the right half show stress with a defined force over a cycle time. It can be clearly seen that at a defined load (in the example 1.0 kN) of a material sample after certain load periods A, B, C, and D (sectors I, II, III and IV), a typical slope of the function in the individual characteristic sections. The slope increase of the function indicates a steadily increasing component fatigue, which finally leads to breakage of the sample at point D. The four areas are therefore criteria to be used for the assessment of the damage.

While in zone I an absolute uncritical increase in strain (flow) can be observed, starting from point A in zone II an uncritical partial damage of the component begins, which starts at point B in Zone III is noticeably tightened and can already be described as critical. Upon reaching zone IV at point C, an already significant failure of the component occurs, which at point D leads to the failure of the operability.

reference curves of course this type can also be created with samples of steel cord connections, in which with the help of dynamic testing machines (Hydropulser) corresponding graphs are recorded. It is crucial that the exam almost perfectly reflects the practical conditions.

Test bench tests carried out in a higher tribological test category (Worksheet No. 7 of the Tribology Society (GfT)) DIN 22110 , T3 using the inventive arrangement of Elastomerencodern allow in addition to the laboratory tests in a tribological test chain, the creation of reference curves that greatly facilitate the determination of the damage situation on a belt conveyor.

6 shows the scheme of a belt conveyor 20 with alternative possibilities for positioning the sensors 15 to his drives. Depending on the design and arrangement of the drive situations are in accordance with DIN 22101 these are referred to as head or rear drives (depending on the bulk material conveying direction), wherein rear drives are usually assigned to the bulk material feeding station at the beginning and head drives the bulk material discharge at the end of the conveying path.

The above lying conveying zone of the belt conveyor is referred to as upper run, the lower bulk-free zone as Untertrum. For the purpose of safe bulk transport, the upper zone is usually troughed, d. h at the edges each bent by a certain angle upwards. The positioning of the sensors 15 has to adapt to these conditions so that both the overload of bulk material largely avoided as well as the zones highest belt transmission forces, depending on the type of drive metrologically be achieved safely.

All in the present description also the marginal values. The features mentioned in the foregoing and Exemplified embodiments of the present invention Invention may be partially or wholly as each other combined to form further embodiments, which are adapted to corresponding applications of the invention. Provided such embodiments for a person skilled in the art result from the aforementioned embodiments are intended this implicit as with the aforementioned embodiments disclosed apply.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - US 4020945 [0013]
• - DE 19603578 [0014]
• - DE 102004061367 [0016]
• - DE 2004001899 [0017]
• WO 2005/023688 [0017]
• US 4854446 [0018]

Cited non-patent literature

• - DIN 22110 [0119]
• - DIN 22101 [0120]

Claims (31)

Device for nondestructive detection of an operating state of elastic components ( 9 ), in particular conveyor belts, conveyor belts or belts comprising: - at least one elastic component ( 9 ), which has a band-shaped shape and in a band circumferential direction at least a first measuring range ( 3 ) and at least one second measuring range ( 1 ), wherein in the measuring ranges ( 1 . 3 ) of the elastic member ( 9 ) Elastomeric encoder ( 8th . 8th' ), - at least one sensor station ( 15 ), with the elastomer encoders ( 8th . 8th' ) outgoing magnetic fields when passing the sensor station ( 15 ) are detectable and unchangeable in output signals, and - at least one process unit ( 16 ) supplied by the sensor unit ( 15 ) received signals, processed into strain data, and thus a first elongation of the Elastomerecoder ( 8th ), which are located in a first measuring range, characterized in that the process unit ( 16 ) determines a first strain difference between the first strain and a first predetermined strain value, or a second strain of the elastomeric encoder ( 8th' ), which are located in a second measuring range of the elastic member, determined and a second expansion difference between the first elongation and the second elongation determined, and determined based on the determined elongation difference, an operating condition of the elastic member. Apparatus according to claim 1, wherein the first measuring range ( 3 ) is an area in which two ends of the elastic member ( 9 ), wherein when the determined first strain difference exceeds a first predetermined value or the determined second strain difference exceeds a second predetermined value, the process unit (16) 16 ) at least a predetermined operating condition signal is output. Apparatus according to claim 1 or 2, wherein the operating condition signal corresponds to a current strain state or a strain state, wherein the first strain difference exceeds the first predetermined value or the second strain difference exceeds the second predetermined value. Device according to at least one of claims 1 to 3, wherein the with the sensor station ( 15 ) detectable magnetic fields alternating polarity, the elongation of the elastic member ( 9 ) simultaneously with the rotational speed of the elastic member ( 9 ) is determinable, and a second, parallel embedded, barcode magnetized elastomeric encoder and at least one additional sensor is provided in the sensor station, wherein with the additional Elastomerencoder a band section is uniquely identifiable. Device according to at least one of the claims 1 to 4, with the strain localized, preferably with one Spatial resolution of a pole width, of a maximum of 50 mm, determinable is particularly preferably with a spatial resolution of two Pol widths of a maximum of 100 mm, can be determined. Device according to at least one of claims 1 to 5, wherein the elastomeric encoder ( 8th ) is produced by adding a filler, wherein the filler is strontium ferrite (SrFeO) and / or an iron alloy (NdFeB), wherein the elastomeric encoder ( 8th ) by adding a filler of 20 to 40 vol.% Strontiumferrit (SrFeO), but preferably 30 vol.% Strontiumferrit (SrFeO), and / or 5 to 30 vol% iron alloy (NdFeB) modified elastomer mixture is produced and non-magnetic Material is covered. Device according to at least one of claims 1 to 6, wherein the elastomeric encoder ( 8th ) is present as a band or plate with a thickness of 1 mm to 5 mm and dimensions preferably of 1000 mm length and 100 mm width and / or composed of such bands and / or plates. Device according to at least one of claims 1 to 7, wherein the pole widths or pole spacings of the elastomeric encoder ( 8th ) of 20 mm to 50 mm, but preferably 40 mm. Device according to at least one of claims 1 to 8, in which the alignment of the elastomeric coders ( 8th ) at most 5 ° from the conveying direction or driving direction of the elastic member ( 9 ) deviates. Device according to at least one of claims 1 to 9, wherein a width of the elastomeric encoder ( 8th ) to a measuring width of the sensor station ( 15 ) is adaptable such that in the event of extreme belt misalignment of the elastic component ( 9 ) the sensor station ( 15 ) the measuring range of the Elastomerencoders ( 8th ) is no longer reached and thus an error message can be triggered. Device according to at least one of claims 1 to 10, wherein the elastomeric encoder ( 8th ) like that is coded that its place of installation is clearly identifiable. Device for conveying goods consisting of an elastic component ( 9 ), which has a band-shaped shape and in a band circumferential direction at least a first measuring range ( 3 ) and at least one second measuring range ( 1 ), and in the measuring ranges ( 1 . 3 ) of the elastic component Elastomercoder ( 8th . 8th' ), wherein - with at least one sensor station ( 15 ), from the elastomere coders ( 8th , 8th' ) outgoing magnetic fields when passing the sensor station ( 15 ) are detectable and unchangeable in output signals, wherein - at least one process unit ( 16 ) supplied by the sensor unit ( 15 ) received signals, processed into strain data, and thus a first elongation of the elastomeric encoder ( 8th ) which are located in a first measuring range, characterized in that the process unit ( 16 ) determines a first strain difference between the first strain and a first predetermined strain value, or a second strain of the elastomeric encoder ( 8th' ), which in a second measuring range of the elastic member ( 9 ), determines and determines a second expansion difference between the first elongation and the second elongation, and determines an operating state of the elastic member based on the determined elongation difference. Apparatus according to claim 12 with at least one running side ( 14 ), and at least one supporting side ( 13 ), whereby between the running side ( 14 ) and the supporting side ( 13 ) elastic elastomerscoder ( 8th . 8th' embedded) which are suitable for outputting alternating magnetic signals, and the first measuring range ( 3 ) is an area in which two ends of the elastic member ( 9 ) are interconnected. Device according to claim 12 or 13, characterized in that the elastomeric coders ( 8th . 8th' ) are embedded in a certain laying scheme, which corresponds to the arrangement of sensors (S1, S2) of a sensor station ( 15 ) corresponds. Device according to at least one of claims 12 to 14, characterized in that via the elastic member ( 9 ), at least three elastomeric coders ( 8th . 8th' ) in transitional zones ( 4 . 4 ' ), which extend into deflection zones of ropes ( 5 ) or an offset zone of cable ends ( 6 ) and / or in cable end-of-travel zones ( 7 ) are located. Device according to at least one of claims 12 to 15, characterized in that between connections of the device at least three reference elastomere coders ( 8th' ) are arranged respectively in the middle and in the right and left edge regions. Device according to at least one of claims 12 to 16, characterized in that the elastomeric encoder ( 8th ) in a transition zone ( 4 ) is anchored with one half of its length in one side of the belt and with the other half in a connecting side. Sensor station ( 15 ), with elastomeric encoders ( 8th , 8th' ) outgoing magnetic fields as they pass the sensor station ( 15 ) are detectable and immutable into output signals, the elastomere encoders ( 8th . 8th' ) in measuring ranges ( 1 . 3 ) of an elastic component ( 9 ), which has a band-shaped shape are embedded, wherein the elastic member ( 9 ) in a band circumferential direction at least a first measuring range ( 3 ) and at least one second measuring range ( 1 ), wherein a process unit ( 16 ) supplied by the sensor unit ( 15 ) received signals, processed into strain data, and thus a first elongation of the elastomeric encoder ( 8th ) located in a first measuring range ( 3 ), characterized in that the process unit ( 16 ) determines a first strain difference between the first strain and a first predetermined strain value, or a second strain of the elastomeric encoder ( 8th' ), which are located in a second measuring range of the elastic member, a second expansion difference between the first elongation and the second elongation determined, and based on the determined elongation difference determines an operating condition of the elastic member. Sensor station ( 15 ) according to claim 18, characterized in that the sensor station ( 15 ) on a belt conveyor ( 20 ) is positionable, and depending on the head or rear drive situation, both on the running side of an upper run and the running and supporting cables of a lower run, the belt conveyor ( 20 ), or wherein the sensor station ( 15 ) depending on the plant situation in the vicinity of a belt conveyor drum ( 10 ), a roller system ( 11 ) and / or a pressure roller in the form of a support or Anpresstrommel ( 12 ) is positionable, with their distance to the running side ( 14 ) of the conveyor belt ( 9 ) is minimal and / or the sensor station ( 15 ) rests directly on this. Sensor station ( 15 ) according to claim 18 or 19, characterized in that the sensor station ( 15 ) optionally traversing movable as a single station, and / or permanently installed as a triple station, each with a single station in the edge regions and a single station in the central region, can be arranged. Sensor station ( 15 ) according to at least one of claims 18 to 20, characterized in that the sensor station ( 15 ) comprises at least two sensors (S1, S2) with a predetermined sensor spacing. Sensor station ( 15 ) according to at least one of claims 18 to 21, characterized in that the sensors (S1, S2) Hall sensors of ratiometric linear design. Device according to at least one of claims 1 to 11 and 18 to 21, wherein with the process unit ( 16 ) the data can be forwarded to a plant-specific operating data acquisition system, wherein information on any disturbance situations are available, due to which an emergency shutdown of the plant is executable with a plant control. Method for nondestructive detection of an operating state of elastic components ( 9 ), in particular of devices according to claim 12, with the steps - detecting a first elongation of elastomer encoders ( 8th ), which in a first measuring range ( 3 ) of an elastic component ( 9 ) determining a first strain difference between the first strain and a first predetermined strain value, or detecting a second strain of elastomer encoders ( 8th' ), which in a second measuring range ( 1 ) of the elastic member ( 9 ) and determining a second expansion difference between the first elongation and the second elongation, and - determining an operating state of the elastic component ( 9 ) based on the determined strain difference, - output of at least one operating state signal when the determined first strain difference exceeds a first predetermined value or when the determined second strain difference exceeds a second predetermined value. The method of claim 24, wherein the elongation of the elastic member ( 9 ) and the rotational speed of the elastic member ( 9 ) at the same time. Use of an elastomeric encoder ( 8th ) for the strain measurement of elastic components ( 9 ), characterized in that the elongation of an elastic member ( 9 ) based on an elongation of at least one Elastomerencoders ( 8th . 8th' ) is detectable. Use according to claim 26, wherein the elongation of the elastic member ( 9 ) simultaneously with the rotational speed of the elastic member ( 9 ) is detectable. Use according to claim 26 or 27, wherein the elastomeric encoder ( 8th ) is produced by adding a filler, wherein the filler is strontium ferrite (SrFeO) and / or an iron alloy (NdFeB), wherein the elastomeric encoder ( 8th ) by adding a filler of 20 to 40 vol.% Strontiumferrit (SrFeO), but preferably 30 vol.% Strontiumferrit (SrFeO), and / or 5 to 30 vol% iron alloy (NdFeB) modified elastomer mixture is produced and non-magnetic Material is covered. Use according to at least one of claims 26 to 28, wherein the elastomeric encoder ( 8th ) is present as a band or plate with a thickness of 1 mm to 5 mm and dimensions preferably of 1000 mm in length and 10 to 100 mm in width and / or can be assembled from such bands or plates. Use according to at least one of claims 26 to 29, wherein the pole widths or pole spacings of the elastomeric encoder ( 8th ) preferably from 100% to 400% of the effective sensor distance. Use according to at least one of claims 26 to 30, characterized in that the orientation of the elastomeric encoder ( 8th ) at most 5 ° from the conveying direction or direction of rotation of the elastic member ( 9 ) deviates.