Special timing belts with steel or Covar reinforcements are often used to transmit enormous forces over long distances. They offer special properties that are essential for large industrial applications. Optimal power transmission depends on the belt tension. A permanently perfectly adjusted belt tension ensures a long service life and reduces wear. However, control and maintenance measures are essential. One critical factor is the belt tension, also known as belt tension. It is usually measured with a tension meter, but only during maintenance and when installing new components, not during continuous operation.
The engineers responsible for the “ZugKraftSensor” project set themselves the challenge of integrating miniaturized silicon strain sensors with dimensions of 500 µm x 500 µm into timing and transmission belts to determine belt tension. A connection technology was developed for the silicon-based strain gauge sensors (Si-DMS) developed in-house. It guarantees direct force and material-locking coupling between the sensors and the flexible carrier elements in order to ensure precise and reliable detection of force changes such as elongation and tension. Depending on the design variant, the sensors and contact surfaces are encapsulated or covered to protect them from external influences. As part of the practical evaluation, the tensile force sensor was used on the tension member up to a load of approx. 35 kN.
The “ZugKraftSensor” project created a technology platform for monitoring belt tension in drive technology systems such as those used in heavy mechanical engineering applications, for example machining centers with various cutting and milling machines or long conveyor belts in packaging and bulk goods systems. Depending on the diameter of the existing tension members in the belt, different mounting brackets and adapted electronic circuit boards are available for sensor contacting.
By monitoring the mechanical tension, maintenance intervals can be planned precisely, material fatigue can be detected at an early stage and unplanned downtimes can be avoided.
The research and development work described was funded by the Federal Ministry for Economic Affairs and Climate Action (BMWK) as part of the “Sensors for belt tension monitoring” (ZugKraftSensor) research project.
Funding code: 49MF210167
