Patent Publication Number: US-2015081166-A1

Title: Wear monitoring system for a track roller

Description:
TECHNICAL FIELD 
     The present disclosure relates to a wear monitoring system of an undercarriage component, and more particularly to a wear monitoring system for a track roller. 
     BACKGROUND 
     A mobile machine may be used to perform various types of work on different worksites, such as, a construction site, a demolition site, a mining site, or a landfill site. For example, a bulldozer may be used to push soil and rock on a construction site. Operation of the mobile machine may result in wear or damage to various components, including components of an undercarriage assembly of the mobile machine, such as, track links and roller assemblies. For example, as a track assembly operates, a surface of each track link may wear away through contact with other components of the track assembly, machine, and/or outside materials (e.g., the ground). 
     It is known to service or replace a machine component, for example, when the component exceeds its expected lifetime (based on the age of the component or number of hours of use experienced by the component), or based on the results of inspection or evaluation of the component. The evaluation of whether the component has undergone sufficient wear for replacement thereof may be determined based on manual inspection of the component. Alternatively, a diagnostic system associated with the component may be used to determine if the component has undergone wear. 
     U.S. Pat. No. 6,360,850 describes a progressive brake lining wear and temperature sensor having a plurality of parallel arranged spaced apart resistors in connection with a sensing circuit. Each resistor is mounted onto a PC board which in turn is encapsulated within a single molding. A thermistor is also mounted onto the PC board within the molding to sense lining temperature. The thermistor is connected to a ground lead. The ground lead, resistance lead and thermistor lead emerge from the encapsulated sensor for connection to the sensing circuit. The sensor is disposed within the brake lining and is connected to the brake shoe by a securement clip. As the brake lining progressively wears, the resistors are progressively worn away thus changing the overall resistance of the sensor. The change in resistance indicates state of wear. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the present disclosure, a wear monitoring system for monitoring wear of track roller is provided. The wear monitoring system for the track roller includes a sensing device positioned beneath a top surface of the track roller. The sensing device includes a probe configured to undergo wear along with the top surface of the track roller, a controller circuit configured to monitor an extent of wear of the top surface of the track roller based on the wear of the probe, an antenna configured to transmit a signal indicative of the extent of wear of the track roller, and a power source configured to provide power to the controller circuit. The wear monitoring system further includes a transceiver configured to receive the signal from the antenna and transmit a signal indicative of the extent of wear of the track roller. The wear monitoring system further includes a monitoring device configured to generate an output indicative of the extent of wear of the track roller. 
     Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an exemplary machine having an undercarriage, according to one embodiment of the present disclosure; 
         FIG. 2  is a block diagram of a wear monitoring system, according to one embodiment of the present disclosure; 
         FIG. 3  is a cross-sectional front view of a track roller of the undercarriage provided with a sensing device, according to one embodiment of the present disclosure; 
         FIG. 4  is a cross sectional perspective view of an idler of the undercarriage provided with the sensing device, according to other embodiments of the present disclosure; 
         FIG. 5  is a is a cross-sectional side view of a track shoe of the undercarriage provided with the sensing device, according to other embodiments of the present disclosure; and 
         FIG. 6  is a cross-sectional front view of a drive sprocket of the undercarriage provided with the sensing device, according to other embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. 
       FIG. 1  illustrates an exemplary machine  100 . In the illustrated embodiment, the machine  100  is a track-type tractor. However, present disclosure may be embodied in any type of machine having an undercarriage assembly, for example, skid steers, dozers, excavators, backhoes, track loaders, and the like. The machine  100  includes an upper body  101  supported by an undercarriage  102 . The upper body  101  may include an operator cabin  103 . Further, a power source (not shown), such as an engine, may be disposed in the upper body  101 . The power source may be configured to generate power to propel the machine  100 , and operate a first implement  105  and a second implement  107  of the machine  100 . Further, the first and second implements  105 ,  107  are a blade assembly and a ripper, respectively. However, the concepts of the present disclosure may be embodied in any type of machine having an undercarriage assembly  102 , for example, skid steers, dozers, excavators, backhoes, track loaders, and the like. 
     The undercarriage  102  may include a pair of track assemblies  109  (only one shown) on opposing sides of the machine  100 . The track assembly  109  may include a track  110 , a drive sprocket  106 , at least one idler  120 , a plurality of track rollers  122 , and a frame assembly  124 . The track  110  may form a continuous structure operatively coupled to the drive sprocket  106 , the idlers  120 , and the track rollers  122 . Further, the power source of the machine  100  may transmit power to the drive sprocket  106  via a driving mechanism. The driving mechanism may include a mechanical drive, a hydraulic drive, an electric drive, or a combination thereof. 
     The frame assembly  124  may carry the idlers  120 . The frame assembly  124  may include multiple members (not shown) movable longitudinally relative to one another. During operation, a relative movement between the members of the frame assembly  124  may move the idlers  120  relative to one another. Further, rotation of the drive sprocket  106  may cause the drive the track  110  to move around the drive sprocket  106 , the idlers  120 , and the track rollers  122  to engage a ground surface, and thereby propel the machine  100 . The drive sprocket  106  may be driven in different directions to propel the machine  100  in forward or reverse directions. Further, the machine  100  may be steered by providing differential power to the drive sprockets  106  of the corresponding track assemblies  109 . 
     In an exemplary embodiment, the track  110  may include a plurality of interconnected track links  126 . Adjacent track links  126  may be rotatably coupled together via a track pin assembly  128 . The track pin assembly  128  may be engaged by teeth of the drive sprocket  106  to drive the track  110  around the drive sprocket  106 , the idlers  120 , and the track rollers  122 . 
     The track  110  may further include a plurality of track shoes  130  secured to the track links  126 . Each track shoe  130  may include a connecting portion configured to be secured to one or more of the track links  126  and a ground engaging portion  132  configured to contact the ground. The ground engaging portion  132  may include one or more portions (e.g., grouser bars) that provide increased traction between the track shoes  130  and the ground. It should be understood that the various components of the undercarriage  102 , described above, are purely exemplary and not intended to be limiting of the present disclosure. 
     During operation, one or more undercarriage components, such as, for example, the track rollers  122 , the track shoes  130 , the track links  126 , and the track pin assemblies  128 , may undergo wear. These undercarriage components may require replacement and/or repair based on an extent of wear. The present disclosure relates to a wear monitoring system  200  configured to monitor an extent of wear of one or more undercarriage components, as will be explained hereinafter in detail. 
       FIG. 2  illustrates the wear monitoring system  200  configured to monitor wear of the undercarriage component, according to some embodiments of the present disclosure. In the illustrated embodiment of  FIG. 2 , various components of the wear monitoring system  200  are described. The wear monitoring system  200  includes a sensing device  202 . The sensing device  202  may include one or more tangible, non-transitory hardware components, including one or more central processing units (CPUs) or processors. For example, the sensing device  202  may include a probe  204  configured to directly and/or indirectly measure, sense, and/or otherwise receive information pertaining to wear of an undercarriage component as input. The probe  204  may be a portion of the sensing device  202  that is configured to wear away with wearing of the undercarriage component. For example, the probe  204  may be a resistance member (e.g., one or more resistors) configured such that, as the probe  204  wears away, a resistance value associated with the resistance member changes. This change in resistance may be correlated with an amount of material that has worn away from the undercarriage component. In other embodiments, the probe  204  may take another configuration (e.g., other than being a resistance member, an alternative shape, etc.). Further, in some embodiments, the probe  204  may not be a wear portion, and may be another device configured to detect a wear characteristic (e.g., a depth sensor). 
     The sensing device  202  may further include a controller circuit  206  configured to generate, receive, transmit, and/or modify a signal indicative of an extent of wear detected by the sensing device  202 . For example, the controller circuit  206  may include a signal conditioner, an amplifier, a multiplexer, and/or a converter (e.g., an analog-to-digital (A/D) converter or a digital-to-analog (D/A) converter). In an embodiment, the controller circuit  206  may be configured to detect a change in the resistance value of the probe  204  due to wear. The controller circuit  206  may be further configured to determine an extent of wear of the surface of the undercarriage component based on the change in the resistance value of the probe  204 . It should be understood that these components are exemplary and that additional and/or alternative circuitry components may be used, depending on the configuration of the probe  204 . 
     The sensing device  202  may further include an antenna  208  configured to transmit a signal indicative of the extent of wear of the surface of the undercarriage component. The antenna  208  may be a radio device configured to wirelessly broadcast an output provided by the controller circuit  206 . Alternatively or additionally, an output port (not shown), such as, for example a USB (universal serial bus) port or similar port, may transmit the output provided by the controller circuit  206  through a cable or other connection removably connected to the output port. 
     The sensing device  202  may further include a power source  210  (not shown) configured to provide power to the controller circuit  206 . In an embodiment, the power source  210  may include a battery, such as, a coin-cell type battery. In some embodiments, the power source  210  may additionally or alternatively include a motion-based energy source, such as, a vibration-based energy-harvesting system, to power one or more of the components of the sensing device  202 , and/or may be used to charge a battery of the power source  210 . In yet another embodiment, the power source  210  may include a battery capable of being wirelessly charged (e.g., near-field charging). In this way, the sensing device  202  may be embedded within the undercarriage component while being capable of receiving electrical power from outside, and thus reducing on-board power (e.g., battery) requirements. 
     The wear monitoring system  200  further includes a transceiver  212  in communication with the sensing device  202 . The transceiver  212  may be located remote to the sensing device  202 . In an embodiment, the transceiver  212  may be a radio-frequency (RF) type device and may wirelessly communicate with the sensing device  202  by various methods known in the art, for example, Bluetooth, Near field communication (NFC), infrared, radio waves, cellular networks like GSM, CDMA, WCDMA, HSPA, HSUPA, HSDPA, or any other known wireless communication methods. The transceiver  212  may be configured to receive a signal indicative of the extent of wear of the undercarriage component from the antenna  208 . 
     The transceiver  212  may be further configured to transmit a signal indicative of the extent of wear of the surface of the undercarriage component to a monitoring device  214 . The monitoring device  214  may be a computing device, such as an on-board or an off-board controller. The on-board controller may be a computing device located on the machine  100  (e.g., inside the operator cabin  103 ). For example, the on-board controller may be an electronic control module including at least a processor and a display. The off-board controller may be a similar computing device located away from the machine  100  at a remote location. The off-board controller may also include at least a processor and a display. 
     In an embodiment, the monitoring device  214  may be configured process the signal indicative of the extent of wear, and further generate an output indicative of the extent of wear of the undercarriage component. For example, the on-board or off-board controller may be configured to communicate with the transceiver  212  (e.g., via a wireless network) to receive wear information, which may be displayed to an operator within the operator cabin  103  or at the remote location from the machine  100 . In an example, the output generated by the monitoring device  214  may be an audio, visual, tactile or a combination thereof type feedback. 
       FIG. 3  illustrates a cross sectional view of the track roller  122 , wear monitoring of the track roller  122  through the wear monitoring system  200  according to an embodiment of the present invention is described. The track roller  122  includes a roller body  302 , a pin  304 , and a bushing  306 . The roller body  302  facilitates movement of the track  110  around the undercarriage  102 . The roller body  302  is an example of a roller with a solid roller body in which the roller body  302  is one piece. The roller body  302  includes a plurality of flanges  310 . The track  110  makes contact with the roller body  302  at top surfaces  312  and  314  adjacent to the flanges  310 . The roller body  302  includes end  316  and end  318  opposite to end  316 . The ends  316  and  318  of the roller body  302  are each configured to fit in respective housings (not shown) within the track assembly  109 . With continuous movement of the track  110  relative to the flange  310  as the machine  100  operates, rubbing and frictional forces may tend to wear the top surfaces  312  and  314 . 
     In an embodiment, the wear monitoring system  200  is employed to monitor wear of the surfaces  312  and  314  of the roller body  302 . The sensing device  202  is embedded into or positioned beneath any one or both of the top surfaces  312  and  314  of the track roller  122 . In one embodiment, the sensing device  202  is positioned approximately between 2-200 mm from the top surface  312  adjacent to a cavity  315 . The cavity  315  allows the sensing device  202  to communicate in an open environment via the antenna  208 . In other embodiments, the sensing device  202  may be positioned approximately between 10-50 mm, 50-150 mm, or 100-200 mm from the top surface  312 . For example, as shown in  FIG. 3 , the sensing device  202  may be positioned in such a manner that the probe  204  of the sensing device  202  may be in close proximity or in contact with the top surface  312 . In one embodiment, the probe  204  of the sensing device  202  may be in close proximity or in contact with the top surface  314 . As explained earlier, the probe  204  is a portion of the sensing device  202  configured to wear away with wearing of the top surface  312 . The wearing of the probe  204  is indicative of wearing of the top surface  312 . A person of ordinary skill in the art will appreciate that the sensing device  202  may be held in position beneath the top surface  312  of the track roller  122  using any known method. For example, the sensing device  202  may be placed within a cavity present beneath the top surface  312 . 
     Further, as a threshold wear limit of the top surface  312  of the track roller  122  is reached, the sensing device  202  transmits a signal indicative of the extent of wear of the top surface  312  to the transceiver  212 . The transceiver  212  is further configured to transmit the signal indicative of the extent of wear to the monitoring device  214 . As described earlier, the monitoring device  214  processes the signal indicative of the extent of wear of the surface  312  and further generates an output indicative of the extent of wear of the surface  312  over an on-board or off-board controller. 
       FIG. 4  illustrates the sensing device  202 , embedded within another undercarriage component, according to other embodiments of the present disclosure. The sensing device  202  is positioned within the idler  120 . In the illustrated embodiment, the sensing device  202  may be configured to detect wear of a surface  402  of a tread shoulder of the idler  120 . Accordingly, the probe  204  of the sensing device  202  is configured to contact with the surface  404  of the idler  120 . The sensing device  202  may be positioned approximately between 2-200 mm below the surface  402  adjacent to a cavity  406  of the idler  120 . The cavity  406  allows the sensing device  202  to communicate in an open environment via the antenna  208 . In other embodiments, the sensing device  202  may be positioned approximately between 10-50 mm, 50-150 mm, or 100-200 mm below the surface  404  of the idler  120 . Alternatively, the sensing device  202  may be disposed below surface  404  of the idler  120 . A person of ordinary skill in the art will appreciate that the sensing device  202  may be held in position using any known method. 
       FIG. 5  illustrates the sensing device  202  embedded in the track shoe  130  of the undercarriage, according to an embodiment of the present disclosure. In the illustrated embodiment, the sensing device  202  may be configured to detect wear of a surface  502  of the track shoe  130 . The track shoe  130  may include the ground engaging portion  132  that contacts the ground during travel of the machine  100 . The ground engaging portion  132  may be the grouser bar associated of the track shoe  130 . The sensing device  202  may be positioned approximately between 2-200 mm below the surface  502  adjacent to a cavity  504  of the track shoe  130 . The cavity  504  allows the sensing device  202  to communicate in an open environment via the antenna  208 . In other embodiments, the sensing device  202  may be positioned approximately between 10-50 mm, 50-150 mm, or 100-200 mm below the surface  502  of the track shoe  130 . The sensing device  202  may be disposed proximate the surface  502  of the ground engaging portion  132  such that the probe of the sensing device is in contact with the surface  502  of the track shoe  130 . A person of ordinary skill in the art will appreciate that the sensing device  202  may be held in position using any known method. 
       FIG. 6  illustrates the sensing device  202  embedded on the drive sprocket  106 . In the illustrated embodiment, the sensing device  202  may be configured to detect wear of a sprocket tooth  602 . The drive sprocket  106  is configured to drive the track  110 , i.e. as the drive sprocket  106  rotates; the sprocket tooth  602  maintains variable pushing contact with the track  110 . This may make the sprocket tooth  602  exposed to multitude of variable cyclic loads that may lead to wear thereof. In the illustrated embodiment, the sensing device  202  may be configured to detect wear of a surface  604  of the sprocket tooth  602 , such that the probe  204  of the sensing device  202  is in contact with the surface  604 . The sensing device  202  may be positioned approximately between 2-200 mm below the surface  604  adjacent to a cavity  606  of the sprocket tooth  602 . The cavity  606  allows the sensing device  202  to communicate in an open environment via the antenna  208 . In other embodiments, the sensing device  202  may be positioned approximately between 10-50 mm, 50-150 mm, or 100-200 mm below the surface  604  of the sprocket tooth  602 . The sensing device  202  may be disposed proximate the surface  604  of the sprocket tooth  602 . A person of ordinary skill in the art will appreciate that the sensing device  202  may be held in position using any known method. 
     It may be contemplated that the wear monitoring system  200  may include multiple sensing devices  202  disposed on the corresponding undercarriage components. In an embodiment, the multiple sensing devices  202  may be in communication with a single transceiver  212 . Alternatively, a separate transceiver  212  may be provided for each sensing device  202 . Further, the orientation and dimensions of the sensing device are not limited to that described herein. 
     INDUSTRIAL APPLICABILITY 
     The present disclosure is related to the wear monitoring system  200  for the undercarriage  102  of the machine  100 . The monitoring system  200  may include the sensing device  202  for detecting wear of the undercarriage component. Further, the sensing device  202  may be in communication with a transceiver  212 , the transceiver  212  may further be in communication with a monitoring device  214 . The monitoring device  214  may be configured to generate an output indicative of wear of the undercarriage component. As explained above, the undercarriage component may include, for example, but not limited to, the track link  126 , the idler  120 , the track roller  122 , and the track shoe  130 . 
     The wear monitoring system  200  may enable real time monitoring of wear of the undercarriage component. Further, the sensing device  202  may be an ultrasonic sensor disposed on the undercarriage component, thereby enabling accurate determination of an extent of wear. Extent of wear may indicate whether the undercarriage component requires repair and/or replacement. Further, the wear monitoring system  200  may provide an alert if the undercarriage component requires immediate attention, thereby preventing any possible failures of the undercarriage component. Hence, machine downtimes may be reduced. 
     The wear monitoring system  200  may also be configured to store wear data. The wear data may be accessible in order to optimize maintenance and operation schedules of the machine  100 , determine working life of various undercarriage components etc. Further, manual inspection of the undercarriage components may be reduced. 
     While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.