Patent Publication Number: US-2015066291-A1

Title: Wear monitoring system for undercarriage component

Description:
TECHNICAL FIELD 
     The present disclosure relates to a wear monitoring system of an undercarriage component, and more particularly to a wear monitoring system using an ultrasonic sensor. 
     BACKGROUND 
     Machines are used to perform various operations in different industries, such as construction, mining, transportation, and the like. Such machines may include an upper frame supported on an undercarriage. The undercarriage includes ground engaging members which provide propulsion to the machine. Operation of the machines may result in wear to various components of the undercarriage including the ground engaging members. For example, if the undercarriage includes a track assembly as a ground engaging member, each track link of the track assembly may undergo wear due to contact with other components of the track assembly and/or a ground surface. 
     Such components, which are prone to wear, may be periodically inspected to determine whether the components require repair or replacement. However, periodic inspections may result in machine downtimes. Further, timely identification of wear of the components may not be possible leading to further damage and/or potential failures of the components during operation of the machine. 
     US Patent Publication 2006/0243839 describes a method and apparatus for measuring and monitoring the setting of a crusher, in which method the erosion of the wearing parts of the crusher are monitored by sensors capable of transmitting the measurement data to the crusher&#39;s automatic control system. Based on the received measurement data, the control system adjusts the crusher setting so as to maintain the setting at its predetermined value irrespective of the erosion of the crusher&#39;s wearing parts. The invention also relates to alternative embodiments of wear sensors for the wearing parts of a crusher. The measurement data indicating the amount of erosion in the wearing parts is transmitted wirelessly to the exterior side of the crusher. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the present disclosure, a wear monitoring system for an undercarriage component is provided. The wear monitoring system includes an ultrasonic sensor disposed on the undercarriage component. The ultrasonic sensor is configured to emit ultrasonic waves to detect wear of the undercarriage component. The wear monitoring system further includes a wear monitoring device disposed in communication with the ultrasonic sensor. The wear monitoring device is located remote to the ultrasonic sensor. Further, the wear monitoring device is configured to generate an output indicative of wear of the undercarriage component. 
     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  illustrates an exemplary machine having an undercarriage; 
         FIG. 2  illustrates a wear monitoring system for a track link of the undercarriage, according to an embodiment of the present disclosure; 
         FIG. 3  illustrates a roller of the undercarriage provided with a wear sensor, according to an embodiment of the present disclosure; 
         FIG. 4  illustrates a track pin assembly of the undercarriage provided with a wear sensor, according to an embodiment of the present disclosure; 
         FIG. 5  illustrates a track shoe of the undercarriage provided with a wear sensor, according to an embodiment of the present disclosure; and 
         FIG. 6  illustrates an idler of the undercarriage provided with a wear sensor, according to an embodiment 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 . 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 . In the illustrated embodiment, the machine  100  is a track-type tractor. 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 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 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 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 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 the rollers  122 , the track shoes  130 , the track links  126 , and the track pin assemblies  128 , and the like 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 an undercarriage component, according to an embodiment of the present disclosure. In the illustrated embodiment of  FIG. 2 , the undercarriage component is the track link  126 . The wear monitoring system  200  includes at least one wear sensor  202  and at least one wear monitoring device  204 . The wear monitoring device  204  is located remotely to the wear sensor  202 . The wear monitoring device  204  and the wear sensor  202  are disposed in communication with each other. In an embodiment, the wear monitoring device  204  and the wear sensor  202  may wirelessly communicate with each other 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. In another embodiment, the wear sensor  202  and the wear monitoring device  204  may be connected to each other by a cable, such as an electric cable, a fiber optic cable etc. 
     The wear monitoring device  204  may be positioned anywhere on the machine  100  that allows the wear monitoring device  204  to receive signals from the wear sensor  202 . In an embodiment, the wear monitoring device  204  may be disposed in the upper body  101  of the machine  100 . The wear monitoring device  204  may be installed in the operator cabin  103  of the machine  100 . Alternatively, the wear monitoring device  204  may be mounted on an exterior surface of the machine  100 . In yet another embodiment, the wear monitoring device  204  may be placed remotely from the machine  100 . 
     The wear sensor  202  may be secured to the track link  126  by various methods. In one embodiment, the wear sensor  202  may be at least partially embedded within the track link  126 . In another embodiment, the wear sensor  202  may be mounted on a surface of the track link  126 . The wear sensor  202  may be configured to detect wear of the track link  126  and transmit a signal indicative of wear to the wear monitoring device  204 . In an embodiment, the wear sensor  202  may be an ultrasonic sensor configured to emit ultrasonic waves, schematically shown as arrow ‘A’, in order to detect wear of the track link  126 . 
     In an example, the wear sensor  202  may be configured to detect an extent of wear of the track link  126 , and transmit signals when one or more wear thresholds are detected. Each of the wear thresholds may be indicative of a length of wear, area of wear, or a ratio of a detected dimension to an original dimension of the track link  126 . The wear sensor  202  may be configured to monitor wear of a surface  203  of the track link  126 . As shown in  FIG. 2 , the wear sensor  202  may be placed beneath the surface  203  on the track link  126 . The surface  203  of the track link  126  may be disposed in contact with other undercarriage components, for example, the idler  120 , the roller  122 , the track shoe  130  etc., and may undergo wear out due to abrasion. 
     In operation, the wear sensor  202  may be configured to emit ultrasonic waves and receive reflected ultrasonic waves from the surface  203 . The wear sensor  202  may be further configured determine an elapsed time span between transmission and receipt of the ultrasonic waves. The elapsed time span may vary with progressive wear of the track link  126 . For example, elapsed time span for an unworn undercarriage component may be different to elapsed time for a worn undercarriage component due to change in dimensions of the undercarriage component. The variation in elapsed time span may be correlated to the wear thresholds described above. When a specific wear threshold is reached, the wear sensor  202  may transmit a signal indicative of the extent of wear of the track link  126  to the wear monitoring device  204 . The wear monitoring device  204  may generate an output indicative of wear of the track link  126 . The output may include an alert, for example, an audio, visual or a tactile alert. Further, the output may include a signal to a central server accessible by service personnel, manufacturer or a dealer. Additionally, the wear monitoring device  204  may also store data related to wear of the track link  126  in a memory. The wear monitoring device  204  may include one or more ports which enable an external device to be connected thereto in order to access stored data related to wear. 
     The wear monitoring device  204  may also be configured to transmit information received from the wear sensor  202  to on-board or off-board devices (not shown). For example, the monitoring device  204  may be in communication with a machine controller (not shown). Moreover, the monitoring device  204  may be in communication with smartphones, laptops, or any portable device known in the art. 
     Although, the wear monitoring system  200  including the wear sensor  202  and the wear monitoring device  204  has been described for wear monitoring of the track link  126 , it should be understood that the wear monitoring system  200  can be employed for wear monitoring of any undercarriage component. Various examples of such undercarriage components are described hereinafter in detail. 
       FIG. 3  illustrates the wear sensor  202  installed on the roller  122 , according to an embodiment of the present disclosure. In the illustrated embodiment, the wear sensor  202  is configured to detect wear of the roller  122 . The wear sensor  202  may be in communication with the wear monitoring device  204  (shown in  FIG. 2 ). The wear sensor  202  may be disposed proximate a tread surface  302  of the roller  122 . The roller  122  may support and guide the track links  126  of the track assembly  109  as the machine  100  travels along the ground. In operation, the tread surface  302  of the roller  122  may be in contact with the track links  126 , resulting in wear of the tread surface  302 . The wear monitoring system  200  may monitor wear of the tread surface  302  in a similar manner as explained above in conjunction with  FIG. 2 . 
       FIG. 4  illustrates the wear sensor  202  installed on the track pin assembly  128 , according to an embodiment of the present disclosure. In the illustrated embodiment, the wear sensor  202  may be configured to detect wear of the track pin assembly  128 . The wear sensor  202  may be in communication with the wear monitoring device  204  (shown in  FIG. 2 ). The track pin assembly  128  may include a pin  402  and a bushing  404 . The track pin assembly  128  may pivotally coupled adjacent track links  126 . Various surfaces if the pin  402  and/or the bushing  404  may undergo wear during operation. The wear sensor  202  may be disposed within a center hole  405  of the pin  402 . The wear sensor  202  may be embedded within a wall of the central hole  405 . Alternatively, the wear sensor  202  may be mounted externally on the wall of the central hole  405 . It may also be contemplated that the wear sensor  202  may be placed on any location on the track assembly  109 . In an example, the wear sensor  202  may be configured to detect wear of a surface  406  of the bushing  404 . The wear monitoring system  200  may monitor wear of the surface  406  in a similar manner as explained above in conjunction with  FIG. 2 . 
       FIG. 5  illustrates the wear sensor  202  installed on the track shoe  130 , according to an embodiment of the present disclosure. In the illustrated embodiment, the wear sensor  202  may be configured to detect wear of the track shoe  130 . The wear sensor  202  may be in communication with the wear monitoring device  204  (shown in  FIG. 2 ). 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 . A surface  502  of the ground engaging portion  132  may be prone to wear. The wear sensor  202  may be disposed proximate the surface  502  of the ground engaging portion  132 . The wear sensor  202  may be embedded in the ground engaging portion  132 . Alternatively, the wear sensor  202  may be externally mounted on the ground engaging portion  132 . The wear monitoring system  200  may monitor wear of the ground engaging portion  132  in a similar manner as explained above in conjunction with  FIG. 2 . 
       FIG. 6  illustrates the wear sensor  202  installed on the idler  120 , according to an embodiment of the present disclosure. In the illustrated embodiment, the wear sensor  202  may be configured to detect wear of the idler  120 . The wear sensor  202  may be in communication with the wear monitoring device  204  (shown in  FIG. 2 ). The wear sensor  202  may be disposed on a tread shoulder  602  of the idler  120 . A surface  604  of the tread shoulder  602  may be in contact with the track links  126 , leading to wear of the surface  604 . The wear monitoring system  200  may monitor wear of the surface  604  in a similar manner as explained above in conjunction with  FIG. 2 . 
     It may be contemplated that the wear monitoring system  200  may include multiple wear sensors  202  disposed on corresponding undercarriage components. In an embodiment, the multiple wear sensors  202  may be in communication with a single monitoring device  204 . Alternatively, a separate monitoring device  204  may be provided for each wear sensor  202 . 
     INDUSTRIAL APPLICABILITY 
     The present disclosure is related to the wear monitoring system  200  for an undercarriage  102  component of the machine  100 . The monitoring system  200  may include the wear sensor  202  for detecting wear of the undercarriage component. Further, the wear sensor  202  may be in communication with the monitoring device  204 . The monitoring device  204  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 roller  122 , the track shoe  130  etc. 
     The wear monitoring system  200  may enable real time monitoring of wear of the undercarriage component. Further, the wear sensor  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. 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.