Chain Wear Indicator

grabcad

This proposal outlines a budget-friendly, uncomplicated chain wear indicator for electric chain hoists. The system comprises two parts: a control mechanism that detects and warns of chain failure and clip attachments placed uniformly on the chain. The control system, the main component, includes: 1. Rotation encoder/Motor controller interface 2. Two "Lasers" (directed light like in a laser pointer) 3. Two light sensors 4. Basic microcontroller 5. Warning hardware (e.g., lights or hoist interface) The clips, attachable at equal intervals (like every 5th link), consist of: - Two identical plastic clips that match the chain size - A "corrosion fuse" - a thin, extremely corrosive piece of metal This system works by mounting the plastic clips with corrosion fuses at equal intervals on the chain. The laser, sensor, and controller assembly is mounted internally at the hoist entrance or externally as an accessory. The two lasers are always on, aligned with the clip holes' positions. The microcontroller measures the chain movement based on encoder data. It detects when the clip opening passes by (with a fixed width) using the first sensor (E1). In software, it determines the relationship between motor movement and real chain length. If the data received from the encoder and the clip distance measurement differ significantly, the controller warns the user and/or stops the hoist. Upon installing a new chain, the controller calibrates itself, allowing any chain to be used. Additionally, it checks for corrosion by verifying if light passes through the corrosion fuses when clips pass by (sensor S2/E2). If links have been exposed to a corrosive environment, the "fuse" will corrode earlier and let light through, indicating an early warning. The entire system is cost-effective to manufacture and install, requiring no chain modification. It can be made as an external accessory for existing hoists and detects deformation while clips pass through the controller assembly. The controller calibrates easily with a new chain by pulling it through and gathering data. Clips are reusable with a new chain, and additional clips can improve accuracy. This innovative wear indicator offers simplicity, affordability, and practicality for electric chain hoists.