GB2406843A - Apparatus and method for comparing elongation of two chains - Google Patents

Apparatus and method for comparing elongation of two chains Download PDF

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Publication number
GB2406843A
GB2406843A GB0501521A GB0501521A GB2406843A GB 2406843 A GB2406843 A GB 2406843A GB 0501521 A GB0501521 A GB 0501521A GB 0501521 A GB0501521 A GB 0501521A GB 2406843 A GB2406843 A GB 2406843A
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United Kingdom
Prior art keywords
chain
elongation
sensors
markers
control unit
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Granted
Application number
GB0501521A
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GB0501521D0 (en
GB2406843B (en
Inventor
Paul M Shuffleton
James Lodovico Moruzzi
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Renold PLC
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Renold PLC
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Publication date
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Priority to GB0501521A priority Critical patent/GB2406843B/en
Publication of GB0501521D0 publication Critical patent/GB0501521D0/en
Publication of GB2406843A publication Critical patent/GB2406843A/en
Application granted granted Critical
Publication of GB2406843B publication Critical patent/GB2406843B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/02Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/04Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving
    • G01B7/042Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving for measuring length
    • G01B7/046Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving for measuring length using magnetic means
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00Testing of machine parts
    • G01M13/02Gearings; Transmission mechanisms
    • G01M13/023Power-transmitting endless elements, e.g. belts or chains
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2203/00Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/02Control or detection
    • B65G2203/0266Control or detection relating to the load carrier(s)
    • B65G2203/0275Damage on the load carrier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2203/00Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/04Detection means
    • B65G2203/042Sensors

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Length Measuring Devices With Unspecified Measuring Means (AREA)
  • Devices For Conveying Motion By Means Of Endless Flexible Members (AREA)

Abstract

Chain elongation monitoring apparatus comprises two or more sets of two sensors S1, S2 mounted on a stationary support at a predetermined fixed distance L1 apart for generating electrical signals in response to the detection of at least two markers M1, M2 attached to each chain. The markers are disposed initially at a predetermined distance L2 apart. A control unit is connected to the sensors to receive the signals, and comprises a timer triggered to measure for each chain the elapsed time between the receipt of signals from the sensors. The control unit is configured to measure a first elapsed time value between signals generated by one of the markers passing between the two sensors, and to calculate the speed of each chain from the first elapsed time value and the value of the predetermined distance L1, and is also configured to measure a second elapsed time value between signals generated by the first marker of each chain passing one of the sensors and the second marker of that chain passing one the sensors. The control unit incorporates means for calculating the distance between the two markers on each chain from the determined speed of the chain and the first and second elapsed time values of that chain, and from the distance calculates the elongation of each chain. An alarm signal generator is connected to the control unit to issue an alarm if the elongation of each chain exceeds a threshold value, and the control unit includes means to compare the values of elongation for each chain and generate an alarm signal if the difference between chain elongation values exceeds a threshold value.

Description

CHAIN ELONGATION MONITORING APPARATUS AND METHOD
The present invention relates to chain elongation monitoring apparatus and an associated method.
Chain drive assemblies are used in many applications such as, for example, in conveyor systems used on manufacturing production dines, in transportation systems such as escalators, elevators or leisure rides (roller coasters etc.), and in internal combustion engines for vehicles. In many applications multiple strands of chain will be used in a single drive assembly.
A chain drive assembly typically comprises at least one endless loop chain that passes around spaced wheels one of which is driven in rotation so as to circulate the chain and any components connected thereto. A chain typically comprises a plurality of chain link assemblies that are interconnected by pins that pass through overlapping apertures in adjacent link assemblies.
Over a period of use, a chain will be subjected to wear by virtue of the rubbing friction between adjacent link assemblies and between the pins and the assemblies.
This wear results in elongation of the chain and eventually the chain will have to be replaced to avoid failure of the drive assembly. The rate of wear of a chain is dependent on the nature of the drive assembly in which it is fitted and the loads to which it is subjected. Failure cannot therefore be predicted with any certainty and regular visual inspection and/or manual measurement is required. This is obviously undesirable as it is labour intensive, imprecise and requires operation of the chain drive assembly to be temporarily intenpted.
US 5,49O,590 describes a chain wear monitor in which the length of a section of a chain is measured during regular operation of the chain drive system. The monitor comprises a wheel that is brought into fi- ictional engagement with the chain. The wheel is mounted on a shaft that is connected to an encoder by a flexible coupling.
The encoder translates rotational movement of the shaft into an electrical signal that is passed to a controller for processing. At the same time, the presence of each chain link is detected by a proximity sensor as it passes a predetermined location. The sensor generates a count signal that is passed to a controller for processing. The controller calculates from the distance and count signals a distance measurement per pre selected number of chain links. This arrangement has to be incorporated into the chain drive system and is prone to inaccuracies caused by relative slip between the friction wheel and the chain.
It is an object of the present invention to obviate or mitigate the aforesaid disadvantages and to provide for a method and apparatus for automatically monitoring the elongation of a chain in-situ.
According to a first aspect of the present invention there is provided chain elongation monitoring apparatus for automatically monitoring the elongation of a chain when in operation in a chain drive assembly, the apparatus comprising: first and second sensors mounted on a stationary support at a predetermined fixed distance apart and for generating electrical signals in response to the detection of at least first and second markers attached to the chain, the markers being disposed initially at a predetennincd distance apart; a control unit connected to said sensors so as to receive said signals therefrom; the control unit comprising a timer that is triggered upon receipt of said signals from said sensors so as to measure the elapsed time between receipt of signals from the sensors; the control unit being configured to measure a first elapsed time value between signals generated by one of the markers passing between first and second sensors and to determine the speed of travel of the chain from the first elapsed time value and the value of the predetermined distance between the sensors; the control unit also being configured so as to measure a second elapsed time value between signals generated by the first marker passing one of said sensors and the second marker passing one of the sensors; the control unit incorporating means for calculating the distance between the markers from the determined speed of travel of the chain and the first and second elapsed time values, means for calculating the elongation of the chain by deducting the predetermined distance between the markers from the calculated distance between the markers, and means for comparing the calculated elongation with a predetermined threshold value; and an alarm signal generator connected to the control unit and for issuing an alarm signal if the calculated elongation exceeds said threshold value.
The invention allows the elongation of a chain to be monitored automatically in real time without interruption of the operation of the chain drive assembly and without the need to remove the chain from the drive assembly. It can be used to predict or determine when a particular chain will require replacement and to assist in the diagnosis of faults in a chain drive assembly. Furthermore the apparatus can be used to determine the relative elongation and wear of different sections in a single chain.
The alarm signal may be visual or audible.
Where two or more parallel chains are used in the drive assembly the apparatus can be used to compare the wear of the chains.
Preferably the control unit comprises means for calculating the rate of wear of the chain over a period of use.
The apparatus may further comprise a visual display for displaying the calculated chain velocity, length, rate of wear and/or the presence of alarm signals.
Preferably the calculated elongation is compared with two predetermined thresholds representing different values of chain elongation and the alarm signal generator is designed to issue first and second alarm signals.
The apparatus may have two or more sets of first and second sensors for monitoring wear in two or more chains each having at least two markers. The control unit comprises means for comparing the calculated values of chain elongation and to generate a signal to trigger the alarm signal generator if the difference between the values exceeds a predetermined threshold value Preferably the markers are designed to fit directly or indirectly to the, or each, chain.
In one preferred embodiment the distance between the sensors is equal to the initial predetermined distance between markers and therefore the second elaspsed time value is that between signals generated by the first marker passing the first sensor and the second marker passing the second sensor.
The sensors are preferably inductive or Hall-effect type, although other types may be used.
The control unit may be configured to monitor chain wear at different sections along a chain by using more than two markers, means being provided to calculate the chain elongation at each of the different sections along chain. The control unit may comprise a comparator for comparing the calculated values of chain elongation at each of the different sections along the chain and may generate a signal to trigger the alarm signal generator if one section of the chain is wearing more rapidly than another.
The control unit may also comprise means for calculating the average wear of the chain from the calculated values of chain elongation.
According to a second aspect of the present invention there is provided a method for automatically monitoring the elongation of a chain when in operation in a chain drive assembly, using first and second sensors disposed at a predetermined fixed distance apart and for generating electrical signals in response to the detection of at least first and second markers attached to the chain, the markers being disposed initially at a predetermined distance apart, and using a control unit comprising a timer that is triggered upon receipt one of said signals from one of the sensors so as to measure the elapsed time between receipt of signals from the sensors; the method comprising the steps of: measuring a first elapsed time value between signals generated by one of the markers passing between first and second sensors; determining the speed of travel of the chain from the first elapsed time value and the value of the predetermined distance between the sensors; measuring a second elapsed time value between signals generated by the first marker passing one of said sensors and the second marker passing one of said sensors; calculating the distance between the markers from the speed of travel and the first and second elapsed time values; calculating the elongation of the chain by deducting the predetermined distance between the markers from the calculated distance between the markers; comparing the calculated elongation with a predetermined threshold value; and generating an alarm signa] if the calculated elongation exceeds said threshold value.
According to a third aspect of the present invention there is provided a kit of parts for automatically monitoring the wear of a chain when in operation in a chain drive assembly, the apparatus comprising: first and second markers for connection directly or indirectly to the chain; first and second sensors mounted on a stationary support at a predetermined fixed distance apart and for generating electrical signals in response to the detection of said first and second markers, the markers, in use, being disposed initially at a predetermined distance apart; a control unit connected to said sensors so as to receive said signals therefrom; the control unit comprising a timer that is triggered upon receipt of said signals from said sensors so as to measure the elapsed time between receipt of signals from the sensors; the control unit being configured to measure a first elapsed time value between signals generated by one of the markers passing between first and second sensors and to determine the speed of travel of the chain from the elapsed time value and the value of the predetermined distance between the sensors; the control unit also being configured so as to measure a second elapsed time value between signals generated by the first marker passing one of said sensors and the second marker passing one of the sensors; the control unit incorporating means for calculating the distance between the markers from the determined speed of travel of the chain and the first and second elapsed time values, means for calculating the elongation of the chain by deducting the predetermined distance between the markers from the calculated distance between the markers, and means for comparing the calculated elongation with a predetermined threshold value; and an alarm signal generator for issuing an alarm signal if the calculated elongation exceeds said threshold value.
A specific embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: figure 1 is a schematic representation of the chain elongation monitoring apparatus and the chain of a chain drive assembly shown at three different points in time during its travel.
The exemplary chain elongation monitoring apparatus comprises a pair of inductive or Hall-effect sensors So, S2 disposed near to the chain 10 at a fixed distance Lo apart on a stationary support structure 11 such as, for example, a framework that carries the chain drive assembly. The sensors So, S2 are connected to a control unit 12 that receives and processes the signals from the sensors So, S2 and generates output signals that drive a visual display 13 and an alarm unit 14.
The control unit 12 comprises conventional signal conditioning circuitry, a timer 15, a processor 16 with associated memory, and an output circuit for driving the visual display or alarm unit.
The chain 10 of the chain drive assembly is in the form of an endless loop that passes around at least a pair of wheels (not shown), one of which drives the chain. A section of the chain 10 is represented in figure 1 and is shown as travelling in the direction from left to right.
The chain 10 is fitted with two markers Ma, M2 that are composed of a material to which the sensors are sensitive (e.g. magnetic elements) and are disposed initially at a predetermined distance apart L2. The markers Ma, M2 may simply clip or otherwise fasten directly or indirectly on to the chain.
Before operation of the chain wear monitor the control unit 12 is preprogrammed with the values of distance Lo, the initial distance L2 between the markers, a first threshold wear length La and an ultimate threshold wear length L,,, all the values being stored in the processor memory.
Linen the chain drive assembly is in operation the chain circulates around the wheels and passes the sensors S., S2 from left to right in the view shown in figure 1.
As each marker Me, M2 passes in front of a sensor an electrical signal is generated and passed to the control unit 12.
As marker Ma passes sensor So the control unit 12 starts the timer 15 in response to the signal received. This is represented in figure I by the diagram labelled as t=O. When marker Me then passes sensor S2 the time elapsed in travelling the distance Lo is recorded as to. Shortly after marker M2 passes sensor So and the time elapsed in travelling the distance L2 is recorded as tL2.
The elongation of the chain is then calculated from the recorded elapsed time values tic and tL2 and the pre-programmed values of Lo and L2. The elongation of the chain is calculated as: Lw = (L: .tL2/tL) - L2 Where Lj/tL is the velocity of the chain and is recorded separately by the control unit for information purposes.
The processor 16 continually compares the present calculated elongation Lw of the chain with the first wear length threshold La and when it exceeds the threshold a signal is generated to sound a first alarm signal. Similarly, a comparison is made with the ultimate wear length threshold Lu and when it is exceeded the control unit will generate a second signal to sound a second alarm.
The display continually provides a reading of the current chain velocity, current chain elongation length Lw and the rate of elongation (rate of wear).
The apparatus can be used to monitor the wear of two chains that are running in parallel to drive a conveyor such as, for example, an escalator. In such an application each chain has at least two markers and a pair of sensors mounted in proximity thereto. The control unit receives signals from both sensors and is pre- progranmed with the parameters relating to each chain. The chain wear is monitored in both chains by the control unit. The difference between the two calculated elongation values is determined and compared to a predetermined threshold value Lo.
If this value is exceeded the control unit issues a signal to the alarm signal generator and an appropriate alarm is sounded. This is particularly important in conveyors such as escalators as inequality of wear of the two chains may result in damage to the chain drive assembly or the escalator itself.
The initial distance between the markers L2 may be set at a value greater than, less than or equal to the distance between the sensors Lo. If the distances Lo and L2 are arranged to be equal when the chain is new, the sensors So, S2 will initially generate signals simultaneously and as the chain wears the signal generated by the passage of the second marker M2 past the first sensor So will lag that generated by the first M marker passing the second sensor S2.
It will be appreciated that numerous modifications to the above described design may be made without departing from the scope of the invention as defined in the appended claims. For example, the chain may be fitted with more than two markers and the chain elongation measured for different sections of the chain. An average chain wear may be calculated by the control unit from the measured values.
Moreover, if a comparison is made of the calculated elongation values this method enables identification of a section of chain that is wearing at a greater rate than other sections. Furthermore, the sensors may be of any suitable type for detecting the presence of a marker e.g. optical or laser based.

Claims (18)

1. Chain elongation monitoring apparatus for automatically monitoring the elongation of two or more chains when in operation in a chain drive assembly, the apparatus comprising: two or more sets of first and second sensors mounted on a stationary support at a predetermined fixed distance apart and for generating electrical signals in response to the detection of at least first and second markers attached to each chain, the markers being disposed initially at a predetermined distance apart; a control unit connected to said sensors so as to receive said signals therefrom; the control unit comprising a timer that is triggered upon receipt of said signals from said sensors so as to measure for each chain the elapsed time between receipt of signals fiom the sensors; the control unit being configured to measure a first elapsed time value between signals generated by one of the markers passing between first and second sensors and to determine the speed of travel of each chain from the first elapsed time value and the value of the predetermined distance between the sensors; the control unit also being configured so as to measure a second elapsed time value between signals generated by the first marker of each chain passing one of said sensors and the second marker of that chain passing one of the sensors; the control unit incorporating means for calculating the distance between the markers on each chain from the determined speed of travel of the chain and the first and second elapsed time values, means for calculating the elongation of each chain by deducting the predetermined distance between the markers from the calculated distance between the markers, means for comparing the calculated elongation with a predetermined threshold value; an alarm signal generator connected to the control unit and for issuing an alarm signal if the calculated elongation exceeds said threshold value; and means for comparing the calculated values of chain elongation for each chain and means to generate a signal to trigger the alarm signal generator if the difference between the chain elongation values exceeds a predetermined threshold value.
2. Chain elongation monitoring apparatus according to claim 1, wherein the alarm signal is visual and/or audible.
3. Chain elongation monitoring apparatus according to claim I or 2, wherein the control unit comprises means for calculating the rate of wear of the chain (or chains) over a period of use.
4. Chain elongation monitoring apparatus according to any preceding claim, further comprising a visual display connected to the control unit and for displaying the calculated chain velocity, length, rate of wear and/or the presence of alarm signals.
5. Chain elongation monitoring apparatus according to any preceding claim, wherein means for comparing the calculated elongation compares the calculated value with two predetermined thresholds representing different values of chain elongation and the alarm signal generator is designed to issue first and second alarm signals.
6. Chain elongation monitoring apparatus according to any preceding claim, wherein the distance between the sensors is equal to the initial predetermined distance between markers and the second elapsed time value is between signals generated by the first marker passing said first sensor and by the second marker passing the second sensor.
7. Chain elongation monitoring apparatus according to any preceding claim, wherein the sensors are inductive or Hall-effect type.
8. Chain elongation monitoring apparatus according to any preceding claim, wherein the control unit is configured to monitor chain elongation at different sections along a chain by using more than two markers, means being provided to calculate the chain elongation at each of the different sections along the chain.
9. Chain elongation monitoring apparatus according to claim 8, wherein the control unit comprises a comparator for comparing the calculated values of chain elongation at each of the different sections along the chain and means for generating a signal to trigger the alarm signal generator if one section of the chain is wearing more rapidly than another.
10. Chain elongation monitoring apparatus according to claim 8 or 9, wherein the control unit comprises means for calculating the average wear of the chain from the calculated values of chain elongation.
11. A method for automatically monitoring the elongation of two or more chains when in operation in a chain drive assembly, using two or more sets of first and second sensors disposed at a predetermined fixed distance apart and for generating electrical signals in response to the detection of at least first and second markers attached to each chain, the markers being disposed initially at a predetermined distance apart, and using a control unit comprising a timer that is triggered upon receipt one of said signals from one of the sensors so as to measure the elapsed time between receipt of signals from the sensors; the method comprising the steps of: measuring a first elapsed time value between signals generated by one of the markers passing between first and second sensors; determining the speed of travel of each chain fi om the first elapsed time value and the value of the predetermined distance between the sensors; measuring a second elapsed time value between signals generated by the first marker passing one of said sensors and the second marker passing one of said sensors; calculating the distance between the markers Tom the speed of travel and the first and second elapsed time values; calculating the elongation of each chain by deducting the predetermined distance between the markers from the calculated distance between the markers; comparing the calculated values of chain elongation for each chain and generating a signal to trigger an alarm signal if the difference between the values exceeds a predetermined threshold value
12. A method according to claim 11, further comprising the step of calculating the rate of wear of the chain (or chains) over a period of use.
13. A method according to any one of claims 11 or 12, further comprising the step of displaying the calculated chain velocity, length, rate of wear and/or the presence of alarm signals.
14. A method according to any one of claims 1 1, 12 or 13, further comprising the step of comparing the calculated elongation value with two predetermined thresholds representing different values of chain elongation and issuing first and/or second alarm signals if the respective chain elongation values are exceeded.
15. A method according any one of claims 11 to 14, further comprising the step of monitoring the chain wear at different sections along each chain by using more than two markers, and calculating the chain elongation at each of the different sections along the chain.
16. A method according to claim 15, further comprising the step of comparing the calculated values of chain elongation at each of the different sections along the chain and issuing an alarm signal if one section of the chain is wearing more rapidly than another.
17. A method according to claim] 5 or 16, further comprising the step of calculating the average wear of the chain from the calculated values of chain elongation.
18. A kit of parts for automatically monitoring the elongation of a chain when in operation in a chain drive assembly, the apparatus comprising: first and second markers for connection directly or indirectly to the chain; first and second sensors mounted on a stationary support at a predetermined fixed distance apart and for generating electrical signals in response to the detection of said first and second markers, the markers, in use, being disposed initially at a predetermined distance apart; a control unit connected to said sensors so as to receive said signals therefrom; the control unit comprising a timer that is triggered upon receipt of said signals from said sensors so as to measure the elapsed time between receipt of signals from the sensors; the control unit being configured to measure a first elapsed time value between signals generated by one of the markers passing between first and second sensors and to determine the speed of travel of the chain from the first elapsed time value and the value of the predetermined distance between the sensors; the control unit also being configured so as to measure a second elapsed time value between signals generated by the first marker passing one of said sensors and the second marker passing one of said sensors; the control unit incorporating means for calculating the distance between the markers from the determined speed of travel of the chain and the first and second elapsed time values, means for calculating the elongation of the chain by deducting the predetermined distance between the markers from the calculated distance between the markers, and means for comparing the calculated elongation of each chain; and an alarm signal generator for issuing an alarm signal if the difference between the calculated elongation of each chain exceeds a threshold value.
GB0501521A 2001-07-24 2001-07-24 Chain elongation monitoring apparatus and method Expired - Fee Related GB2406843B (en)

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GB0501521A GB2406843B (en) 2001-07-24 2001-07-24 Chain elongation monitoring apparatus and method
GB0117993A GB2377918B (en) 2001-07-24 2001-07-24 Chain elongation monitoring apparatus and method

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GB0501522D0 (en) 2005-03-02
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GB0117993D0 (en) 2001-09-19
GB2406843B (en) 2005-09-07

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