Contactless belt transmission fault monitoring system with magnetically sensitive sensor

The problems associated with malfunctions in belt drives are considered, and a system for contactless monitoring of the drives condition based on ferromodulation sensitive sensors is proposed. The key factors of belt transmission failures have been investigated, including belt length changes, wear and slippage, fatigue deformations, and changes in the physical and mechanical characteristics of the belt material. The disadvantages of traditional monitoring methods are noted, in particular, the need to shut down measuring equipment, susceptibility to contamination, and insufficient information content of the data obtained. As a solution, a continuous and non-contact monitoring system is proposed based on the use of a complex of ferromodulation sensitive sensors: two sensors for monitoring belt movement, and two additional sensors installed in the area of the pulleys. This makes it possible not only to calculate the absolute belt elongation in a non-contact way, but also to diagnose critical phenomena such as belt slippage relative to pulleys and uneven loading. The proposed mathematical model makes it possible to calculate the instantaneous belt movement speed and its absolute elongation with high accuracy by analyzing the time delays between sensor actuations. The hardware of the system is described, including the device of sensor nodes and the principles of signal processing. Important advantages of the development are the ability to function in conditions of significant electromagnetic interference and variable loads, as well as continuous and contactless monitoring of belt drive malfunctions.

1. Nikatina I.N., Efanov S.A. XLVIII Ogarovskiye chteniya (XLVIII Ogarev Readings), Proceedings of the Scientific Conference, Saransk, December 6–13, 2019, Pt. 1, Saransk, 2020, рр. 515–518. (in Russ.)

2. Zabbarov A.N., Kamalov I.F., Rukavishnikov V.A. Priborostroyeniye i avtomatizirovannyy elektroprivod v TEK i ZHKKH (Instrument Making and Automated Electric Drives in the Fuel and Energy Complex and Housing and Public Utilities), Proceedings of the IX National Scientific and Practical Conference, Kazan, 2024, рр. 496–498. (in Russ.)

3. Ignatovich D.A., Gerasimov A.A. Innovatsionnyye tekhnologii v nauke i obrazovanii (Innovative Technologies in Science and Education), Collection of Scientific Papers of the XI International Scientific and Practical Conference, Rostov-on-Don, 2023, рр. 176–179. (in Russ.)

4. Szczypiński-Sala W., Dobaj K., Kot A. Tribologia, 2017, no. 5, pp. 93–100.

5. Bakholdin A.M., Shakhov S.V., Zorin M.I., Zharikov A.V. Nauchnoye obozreniye. Pedagogicheskiye nauki, 2019, no. 3-4, pp. 12–15. (in Russ.)

6. Mudrov A.G., Zolottsev Yu.K. Tekhnika i tekhnologiya transporta, 2019, no. 3(14), pp. 4. (in Russ.)

7. Abrate S. Mechanism and Machine Theory, 1992, no. 6(27), pp. 645–659.

8. Sabanchiyev Kh.Kh Izvestiya Severo-Kavkazskogo nauchnogo tsentra vysshey shkoly. Tekhnicheskiye nauki, 1981, no. 2, pp. 56–59. (in Russ.)

9. Feng X., Shangguan W.-B., Deng J. et al. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 2017, no. 13(231), pp. 1780–1795.

10. Galadzhev R.S. Peredatochnyye mekhanizmy (Transmission Mechanisms), Moscow, 1966, рр. 24–27. (in Russ.)

11. Martynov V.K. Razrabotka teorii, metodov rascheta i proyektirovaniya sovremennykh peredach treniyem gibkoy svyaz’yu (Development of Theory, Calculation Methods, and Design of Modern Flexible Link Friction Transmissions), Doctor’s thesis, Tula, 2004, 293 р. (in Russ.)

12. Kulikov I.M., Sinyavskiy I.M. Uspekhi sovremennogo estestvoznaniya, 2011, no. 7, pp. 137–138. (in Russ.)

13. Patent RU 2014146408/28, Ustroystvo dlya kontrolya natyazheniya privodnykh remney (Device for Monitoring Drive Belt Tension), A.V. Struchkov, A.A. Klimov, T.T. Eresko, I.A. Grosheva, Published 10.08.2015. (in Russ.)

14. Galadzhev R.S., Ignatenko Yu.A. Peredatochnyye mekhanizmy (Transmission Mechanisms), Moscow, 1971, рр. 81–88. (in Russ.)

15. Patent RU 99118848/28, Remennaya peredacha s datchikami informatsionno-energeticheskogo sostoyaniya (Belt Drive with Information-Energy State Sensors), A.N. Marti, G.M. Vodyanik, Published 10.07.2001. (in Russ.)

16. Wei S., Liao X., Zhang H., Pang J., Zhou Y. Sensors, 2021, vol. 21, рр. 1500.

17. Wang H., Chen S., Zhang S., Yuan Z., Zhang H., Fang D., Zhu J. Sensors, 2017, vol. 17, рр. 2651.

18. Nikol’skii V.V. Teoriya elektromagnitnogo polya (Electromagnetic Field Theory), Moscow, 2020, 400 р. (in Russ.)

19. Bezkorovainy V.S., Livtsov Yu.V., Yakovenko V.V., Shatova N.A. RGRTU Bulletin, 2019, no. 70, pp. 190–197. (in Russ.)

20. Afanasyev Yu.V. Ferrozondovyye pribory (Fluxgate Devices), Leningrad, 1986, 186 р. (in Russ.)

21. Starodubtsev Yu.N., Belozerov V.Ya. Komponenty i tekhnologii, 2008, no. 1, pp. 45–49. (in Russ.)

22. Yamamoto S., Matsushita F. IEEE Transactions on Magnetics, 2022, no. 2(58), art. no. 4000205.

23. Lee J., Kim T.-H. Journal of Electrical Engineering & Technology, 2023, no. 1(18), pp. 543–550.

24. Choudhury P., Kumar R., Singh S. Advances in Manufacturing Technology. Computational Materials Processing and Characterization, 2022, pp. 121–133.