JP2014002028A - Abrasion sensor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an abrasion sensor capable of gradually and accurately measuring an abrasion quantity of a sliding part.SOLUTION: In the abrasion sensor allowed to be fixed so that a tip part is directed to a sliding member of an industrial machine to detect abrasion of the sliding member, a plurality of circuit insulating plates are laminated, one abrasion detecting print line is arranged in each of the plurality of circuit insulating plates, an abrasion detecting print line on a predetermined circuit insulating plate out of the plurality of circuit insulating plates is arranged at a predetermined pitch in a direction vertical to a lamination direction from the tip part of the abrasion sensor against abrasion detecting print lines on the other circuit insulating plates in the plurality of circuit insulating plates, and the abrasion detecting print lines formed on the respective circuit insulating plates are gradually worn successively from an abrasion detecting print line close to the tip part with abrasion of the sliding member.

Description

  The present invention relates to a gauge for measuring wear of a sliding portion of an industrial facility, and more particularly to a wear sensor that can predict a maintenance time by detecting a wear state in stages.

  In order to diagnose the wear state, the sliding part of the industrial machine is inspected by actually disassembling the machine and measuring the wear state of the sliding part. For example, in a vertical pump of a seawater intake facility of a power plant, the vertical state of the vertical pump is once put on land, and the wear state is diagnosed by periodically measuring the gap between the main shaft side and the bearing side.

  However, there is a drawback that much time and cost are required for inspection, and it is desired to develop a method for detecting the actual wear amount of the sliding portion even when the machine is in operation.

  As a method of detecting the wear amount of the sliding part even when the machine is in operation, a thin film resistor having a constant resistance value is laminated at a constant interval in an insulator, and both ends of each thin film resistor are connected to a connecting wire. A method for calculating and displaying the wear amount by correcting the resistance value according to the temperature change with the resistance change and the temperature detection value of the temperature sensor is disclosed. (For example, refer to Patent Document 1). Simply by embedding the wear sensor in the bearing, the amount of wear can be detected easily and accurately. This makes it possible to constantly monitor the amount of wear on the bearing to know when to replace the bearing and prevent troubles from occurring. .

  As another method, a plurality of conductive materials along the longitudinal direction are formed on one side surface of a short insulating base 1 having one end in the longitudinal direction serving as a sliding end surface 1a and the other end serving as a signal lead-in / out end surface 1b. The bodies 21, 22... Are printed in parallel with each other at equal intervals, and the ends of the conductors 21, 22... On the sliding end face 1 a side of the substrate 1 are in relation to the sliding end face 1 a. A plurality of bases 11, 12,... 15 at the center of a cylindrical body formed of an insulating material, using a base for wear amount detection configured so that the position is set in a state inclined at a predetermined angle. Wear is measured in such a manner that the arrangement of the end portions of the conductors 21, 22 ... 2n provided on the substrates 11, 12 ... 15 is sequentially shifted by X mm. An apparatus is disclosed (for example, see Patent Document 2).

  Furthermore, as another approach, in a surface wear detection device for continuously monitoring the amount of wear on the surface of a machine component or element, it can be fixed to a sliding member, and the upper closed end in the machine body. Has a number of conductor loops 1, 2 ′, 3 ′... Having a plurality of conductor loops 1, 2 ′, 3 ′. There is disclosed a detection element that acts on a part and eventually breaks the upper end 1 'of the first or left wire loop first, and then breaks the remaining loops sequentially as wear progresses (for example, patents) Reference 3).

Japanese Patent Laid-Open No. 06-193629 JP 62-083602 A JP 47-031646

  However, according to the method described in Patent Document 1, the stacking direction of the detection elements is the same (parallel) as the stacking direction of the insulator. In the case of this stacking direction, the resolution of wear detection is limited to “thickness of detection element” + “thickness of insulator”. Therefore, the resolution is limited by the thickness of the detection element and the insulator, and there is a problem that the amount of wear below the thickness of the insulator cannot be detected.

  In addition, since a plurality of detection elements are stacked in the vertical direction, a malfunction may occur due to the occurrence of a short circuit due to the abrasion of the print line adhering to the lower print line.

  Further, in the print line arrangement described in Patent Document 2, since a plurality of print lines are arranged in the vertical direction, the print line width and the print line interval are required due to printing technology restrictions, and wear detection is performed. There is a limit to the lower limit of the print line pitch. In other words, the technique of Patent Document 2 is intended only to expand the measurement range (X), and not intended to reduce the detection resolution.

  In addition, since a plurality of print lines are formed on the same substrate, a malfunction may occur due to occurrence of a short circuit due to adhesion of wear debris of the print lines to adjacent print lines.

  Further, according to the method described in Patent Document 3, since a plurality of print lines are formed on the same substrate, the width of the print line is a lower limit of the resolution, which causes limitations due to the print technology. There is a problem that the wear amount below the line width cannot be detected.

  In addition, since a plurality of print lines are formed on the same substrate, a malfunction may occur due to occurrence of a short circuit due to adhesion of wear debris of the print lines to adjacent print lines.

  7 and 8 are diagrams for explaining an example of a malfunctioning mechanism due to wear debris. As shown in FIG. 7, the wear detector C is installed on the bearing B. When the bearing B wears with the wear amount d as the shaft A rotates, the wear detector C wears with the same amount d as the bearing B wears. As the wear detector C wears, the plurality of wear detection print lines a to e shown in FIG. 8 are disconnected in order from the top, and the amount of wear is detected.

  FIG. 8 is an enlarged view of the worn portion D of FIG. As shown in the figure, since the plurality of print lines a to e are formed on the same substrate, it can be seen that the wear waste E of the print line a may adhere to the adjacent print line b and short-circuit.

  The present invention has been made to solve such a conventional problem, and an object of the present invention is to provide a more inexpensive wear sensor capable of measuring the amount of wear of sliding parts of industrial equipment stepwise and accurately. To do.

  The present invention is a wear sensor that can be fixed to a sliding member of an industrial machine with a tip portion thereof, and detects wear of the sliding member, and is formed by laminating a plurality of circuit insulating plates. Each of the circuit insulation plates is provided with one wear detection print line, and the wear detection print lines on the predetermined circuit insulation plates in the plurality of circuit insulation plates are arranged in the plurality of circuit insulation plates. With respect to the print line for wear detection on the other circuit insulating plate, it is arranged at a predetermined pitch in the direction perpendicular to the direction of lamination from the tip of the wear sensor, and a plurality of circuits are attached as the sliding member wears. The wear detection print line formed on each of the insulating plates is gradually worn away from the wear detection print line near the tip.

  According to the wear sensor of the present invention, even if the machine is in operation, the actual wear state of the sliding portion can be monitored constantly and simply by embedding the wear sensor in the bearing, and the parts can be inspected at an appropriate time. And can be exchanged.

  By detecting the disconnection of the circuit corresponding to the wear amount of the sliding member, the actual wear amount of the sliding portion can be detected in a stepwise manner, and the change tendency of the wear amount can be grasped. In addition, since the wear sensor of the present invention can arbitrarily design the distance from the tip of the print line of each layer, the resolution can be increased and a minute wear amount can be detected.

  Further, since the detection method is a simple method using only electrical resistance, it is resistant to disturbance and easy to determine wear. Since the wear sensor has a simple structure, it can be manufactured at low cost.

  In addition, according to the wear sensor of the present invention, the layers that print the print line and the layers that do not print can be alternately laminated, so that a wide space between the print lines can be designed and malfunctions can be prevented. Then, the amount of wear of the bearing is constantly monitored to know the replacement time of the bearing, thereby preventing troubles from occurring.

It is a figure which shows the external appearance of the abrasion sensor of embodiment of this invention. It is AA sectional drawing of Fig.1 (a). It is a figure which shows an example of the attachment to the industrial machine of the wear sensor of embodiment of this invention. It is the figure which expanded the wear part D of the wear sensor of this embodiment of FIG. It is a figure which shows arrangement | positioning of the print line of the abrasion sensor of other embodiment of this invention. It is a figure which shows arrangement | positioning of the print line of the abrasion sensor of other embodiment of this invention. It is a figure explaining an example of the mechanism of the malfunctioning by abrasion waste. It is a figure explaining an example of the mechanism of the malfunctioning by abrasion waste.

  Hereinafter, a wear sensor according to an embodiment of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a view showing an appearance of a wear sensor according to an embodiment of the present invention. FIG. 1A is a perspective view of the main body portion of the wear sensor of the present embodiment, and FIG. 1B is an exploded perspective view of the main body portion of the wear sensor of the present embodiment.

  The wear sensor 100 is configured by laminating circuit printed boards 101 to 105. The circuit printed circuit boards are laminated so that the tip positions are the same. The circuit printed boards 101 to 105 are appropriately selected from a rigid board or a flexible board depending on a sliding member (hereinafter also referred to as a target) to be measured.

  Note that the wear sensor according to the present embodiment may alternately stack a substrate on which a circuit is printed and a substrate on which a circuit is not printed.

  When a rigid board is used for the circuit printed boards 101 to 105, the wear sensor itself has a certain rigidity, so that the wear sensor can be fixed to the target without providing a special holding member.

  When a film-like flexible board is used for the circuit printed boards 101 to 105, the wear sensor itself can be deformed, so that the wear sensor can be attached to the target regardless of the shape of the non-measurement member. It becomes. Further, since it is in the form of a film, the wear powder generated from the wear sensor is minute and can be made of a material softer than the target, so that the influence on the wear of the target and the counterpart material is extremely small.

  As rigid substrates, general substrates include bakelite substrates, phenol substrates, epoxy substrates (paper epoxy, glass epoxy, etc.), glass composite substrates, glass cloth substrates, ceramic substrates (alumina, etc.), and metal substrates (iron, copper, etc.) , Aluminum, stainless steel, etc.) can be used.

  In addition, as a rigid substrate material, as a special resin substrate material, polyimide resin, aramid resin, fluorine resin, PPE (polyphenylene ether) resin, PPO (polyphenol oxide) resin, BT (bismaleimide triazine) resin, etc. It is possible to use.

  Other rigid substrate materials that have been developed in recent years include cyanate resin, maleimide resin, polyolefin, liquid crystalline polyester, polyethylene naphthalate, acrylic resin, PVB laminate, PEEK, polyquinoline, norbornene. Polyparabanic acid, bisallyl nazide, and the like can be used.

  As the flexible substrate material, polyimide film, aramid film, glass cloth, epoxy resin, glass fiber, and the like can be used. For example, a resin, glass fiber or the like formed to a thickness of about 0.2 mm per layer is used.

  As shown in FIG.1 (b), the printed lines 1-5 are provided in each circuit printed circuit board 101-105 of the abrasion sensor 100 of this embodiment, respectively. Via holes 1b to 6b are provided at lower ends of the print lines 1 to 5 below the wear sensor main body 100, and electrical connection between circuit printed boards 101 to 105 to be described later is achieved. These print lines 1 to 5 constitute a wear sensor circuit portion as a whole.

  FIG. 1B is a diagram illustrating an arrangement of print lines of the circuit printed boards 101 to 105.

  A printed line 1 is formed on the circuit printed board 101, a printed line 2 is formed on the printed circuit board 102, a printed line 3 is formed on the printed circuit board 103, and a printed line is printed on the printed circuit board 104. A line 4 is formed, and a printed line 5 is formed on the circuit printed board 105. Further, the upper ends (wear detection portions) of the print lines 1 to 5 are referred to as wear detection print lines 1a to 5a, respectively.

  FIG. 2 is a cross-sectional view taken along line AA in FIG. As shown in the drawing, the widths of the wear detection print lines 1a to 5a of the wear sensor of this embodiment are W, and are arranged on the circuit printed boards 101 to 105 with a gap G, respectively. Note that W and G may have the same length, and may be appropriately changed for each substrate according to measurement conditions.

  Furthermore, the lower ends of the wear detection print lines 1a to 5a are respectively arranged at positions L1 to L5 from the front end portion (the portion that first contacts the object to be measured) of the wear sensor 100 of the present embodiment.

  The wear sensor 100 of the present embodiment can be manufactured using a general printed circuit board manufacturing technique.

  In the present embodiment, the number of wear detection print lines is five. However, the present invention is not limited to this, and the number of wear detection print lines can be arbitrarily set. Similarly, the intervals between the wear detection print lines 1a to 5a can be arbitrarily set. In the present embodiment, each of the wear detection print lines 1a to 5a is linear, but may be an arbitrary curve or shape in accordance with the shape of the constituent member for measuring wear.

  FIG. 3 is a diagram illustrating an example of attachment of the wear sensor of the present embodiment to an industrial machine. A is a rotating shaft in an industrial machine, B shows a bearing. As shown in the figure, the print line 1 is connected to the connection unit 101-1 of the measurement unit 101 via the via hole 1b, and one circuit (wear) via the via hole 6b connected to the connection unit 101-6. Sensor circuit portion). Similarly, the print lines 2 to 5 are connected to the connection units 101-2 to 101-5 of the measurement unit 101 via the via holes 2b to 5b, respectively, and via the via holes 6b connected to the connection unit 101-6. , Each forming one circuit (abrasion sensor circuit portion).

  The measurement unit 101 measures the resistance values of the print lines 1 to 5, and detects the wear of the wear detection print line 1 a that is the first-stage print line by insulating the print line 1. Similarly, by the insulation of the print lines 2 to 5, the wear of the wear detection print lines 2 a to 5 a, which are the second to fifth-stage print lines, is detected.

  When the operation of the industrial machine is actually started, wear of the inner surface of the bearing B proceeds due to sliding between the rotary shaft A and the bearing B, and when the wear progresses L1 shown in FIG. The wear detection print line 1a located near the moving surface is first worn. Due to wear of the print line 1a for wear detection, the electrical connection of the print line 1 is cut off, and the resistance value of the print line 1 becomes infinite. When the wear detection print line 1a is first worn, it can be used as a reference for the amount of wear thereafter.

  As the bearing B wears, the wear sensor 100 further wears, and when the wear has progressed to L2, the wear detection print line 2a disappears due to wear, and the electrical connection of the print line 2 is cut off. Thereby, the resistance value of the print line 2 becomes infinite. That is, by detecting that the resistance value of the print line 2 has become infinite, it is possible to detect that the wear has progressed L2.

  Thereafter, as the wear of the wear sensor 100 progresses, the wear detection print lines 3a to 5a wear, and the continuity of the print lines 3 to 5 is lost in sequence, so that it is possible to detect that the wear has progressed L3 to L5.

  Since the wear amounts L1 to L5 of the wear sensor 100 are the same as the wear amount of the bearing B, the wear amount of the bearing B is detected stepwise by detecting the wear of the wear sensor 100 step by step. Can do.

  In general, since it is easy to detect a state where the circuit is disconnected, that is, a state where the resistance value is infinite, reliable wear can be detected.

  FIG. 4 is an enlarged view of the wear portion D of the wear sensor of the present embodiment shown in FIG. As shown in the figure, since the print line 1 and the print line 2 are formed on different substrates 101 and 102, there is an interval l1 between the two print lines. It is possible to prevent a short circuit from being attached to the line 2.

  Fig.5 (a) is a figure which shows arrangement | positioning of the print line of the abrasion sensor of other embodiment. As shown in the figure, the print lines 1a to 3a each have a width of W and are arranged with an interval (pitch) G having a value smaller than W. Thereby, the resolution of the wear sensor 200 becomes G, and a resolution of the print line width W or less can be realized.

  For example, when a general printing technique is used, the pitch of the printed lines on each circuit printed board is about 0.1 mm, but the printed lines are formed on a plurality of printed circuit boards by shifting the arrangement by 0.05 m. As a result, the wear detection print lines 1a, 2a, 3a of the wear sensor main body 200 are arranged at a pitch of 0.05 mm, and a higher level of detection resolution of 0.05 mm can be obtained. This makes it possible to produce a high-resolution wear sensor at low cost without using advanced printing technology.

  As described above, according to the wear sensor of this embodiment, the print line is divided into a plurality of circuit printed circuit boards to change the detection signal for each layer, or to obtain a detection resolution that is impossible with one layer. It becomes possible.

  Further, by designing the distance from the front end of the print line of each printed circuit board, it is possible to detect a minute amount of wear corresponding to the measurement object.

  FIG. 5B is a diagram illustrating an arrangement of print lines of a wear sensor according to another embodiment. As shown in the figure, the order from the tip of the wear sensor 300 of the print lines 1a to 5a for wear detection and the order of stacking of the printed boards 301 to 305 are partially or completely different, and the layers of the print lines 1a to 5a are different. This is intended to increase the distance. As shown in FIG. 5B, in this embodiment, the distance between the wear detection print line 1a and the wear detection print line 3a to be worn next is l2, and the interlayer distance is larger than the distance l1 shown in FIG. ing. By increasing the interlayer distance, it is possible to more effectively prevent the wear debris of the print line from adhering to other print lines and causing a short circuit.

  Moreover, you may laminate | stack alternately the board | substrate which prints a print line, and the board | substrate which does not. As a result, the space between the print lines can be designed more widely, and malfunctions can be prevented.

  FIG. 6 is a diagram illustrating an arrangement of print lines of a wear sensor according to another embodiment. As shown in the figure, the widths of the wear detection print lines 1 a to 5 a become wider as the distance from the tip of the wear sensor 400 increases. By adopting such a shape, it is possible to design a wear sensor that matches the shape of the measurement object.

  In the present embodiment, only the printed circuit board on which the circuit is formed is stacked, but a support printed circuit board may be further stacked on the outermost layer to improve rigidity and protect the wear sensor main body 100. When a conductor is printed on the surface of a printed circuit board, even if the printed circuit board is worn out, the printed line itself will not be worn off, and the wear may not be detected, but the printed surface on which the printed line is placed is supported. By sandwiching with the printed circuit board, the print line is surely broken, and it is possible to reliably detect wear.

  As described above, according to the wear sensor of the present embodiment, the wear amount of the sliding member can be detected stepwise by detecting circuit disconnection when the wear detection print line is worn. . Since the detection method is a simple method using only electrical resistance, it is resistant to disturbance and easy to determine wear. Further, since the actual amount of wear is measured, accurate measurement without error is possible.

  Since the change in the amount of wear can be grasped step by step, the tendency of the change in the amount of wear can be grasped, and the remaining life of the mechanical system and the optimal maintenance time can be predicted.

  Since the wear sensor of this embodiment can be manufactured using a general printed circuit board manufacturing technique, it can be mass-produced with high quality, high accuracy, and low price.

  And since the circuit layout, which is an electrical configuration, is made integrally on the printed circuit board, there is no risk of measurement errors due to movement of the electrodes due to vibration, etc., and the measurement pitch can be set arbitrarily and accurately. Is possible.

  The above-described embodiments described above can be implemented with various changes and improvements.

  The wear sensor of each of the above embodiments includes bearing wear, machine tool cutting tools, automobile tires and brake pads, general machine sliding parts, general machine clutches and brakes, rolling mill rolls, etc. It is possible to detect wear on the sliding surface of the machine, measure the contact around the center of a long shaft (rotary shaft) and rotating body (gap sensor function), detect wear on railway rails, etc., machine tools The present invention can be widely applied to detection of wear of sliding parts such as guide rails and detection of displacement in the axial direction (thrust) of the shaft.

100 to 400: Wear sensors 101 to 105, 201 to 205, 301 to 305: Circuit printed boards 1 to 5: Print lines 1a to 5a: Wear detection print lines

Claims (5)

A wear sensor that can be fixed with the tip portion directed to a sliding member of an industrial machine and that detects wear of the sliding member,
A plurality of circuit insulating plates are laminated, and each of the plurality of circuit insulating plates is provided with one wear detection print line,
The wear detection print line on a predetermined circuit insulation plate in the plurality of circuit insulation plates is different from the wear detection print line on another circuit insulation plate in the plurality of circuit insulation plates. It is arranged with a predetermined pitch in the direction perpendicular to the direction of the stack from the tip,
Abrasion characterized in that the wear detection print line formed on each of the plurality of circuit insulating plates wears out in stages from the wear detection print line close to the tip as the slide member wears. Sensor.   A plurality of wear detection circuits each including a plurality of circuit insulation plate wear detection print lines in the circuit, and the plurality of wears associated with stepwise wear of the plurality of circuit insulation plate wear detection print lines; The wear sensor according to claim 1, further comprising a wear sensor circuit section in which each of the detection circuits is cut in stages.   The wear sensor according to claim 1, wherein the predetermined pitch is smaller than a width of the print line for wear detection.   The order from the front-end | tip part of the said wear sensor of the said print line for wear detection and the order of lamination | stacking of these circuit insulation boards differ in part or all, The one in any one of Claim 1 to 3 characterized by the above-mentioned. The described wear sensor. 5. The wear sensor according to claim 1, wherein the width of each of the wear detection print lines becomes wider as the distance from the front end portion increases.

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