Note: Descriptions are shown in the official language in which they were submitted.
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CONVEYOR IDLER ROLLER MONITORING ASSEMBLY
TECHNICAL FIELD
[0001] The present invention relates to conveyor idler rollers used in belt
conveyors for bulk
materials handling and, more particularly, to an electronic monitoring system
for conveyor idler
rollers.
BACKGROUND
[0002] Conveyors are commonly used to transport a wide range of materials
(such as
minerals including coal, iron ore, phosphate or bauxite) through various
stages of the transport
chain, commonly between a mine rock face in a pit over long distances for
unloading at a
processing station and/or a means of transport such as ships at port. They are
also used for
agricultural purposes including for the transport of grain to and from silos.
[0003] An example of a pit conveyor 10 is shown in figure 1. Pit conveyors
are commonly
around twenty kilometres long, but some conveyors can be much longer. The
conveyor 10
comprises a belt 12 which carries excavated material 14, such as ore. The belt
12 is driven by
rollers 16. Each roller 16 has a head 18 which support a bearing 20 at each
end of the roller 16.
Each bearing 20 is mounted on an axle 22 on which the roller rotates.
[0004] Rollers require regular replacement because they tend to operate in
harsh
environments. The bearings of the rollers may fail. Sometimes the head comes
away from the
end of the tube. On occasions, the tube of the roller wears out and breaks.
[0005] Two key causes of conventional conveyor idler roller failure are,
first, the end cap
that holds the axle in place breaks away from the end of the housing; or the
bearings held in
place by the end cap (that hold the axle that passes through the centre of the
idler roller) fail
because of the loads being placed on them or debris works its way into the
bearing through the
sealing arrangement.
[0006] The common way to identify whether an idler roller has failed is by
regular manual
inspections. However, systems have been developed to automatically monitor the
failure of
conveyor idler rollers. For example, Vayeron Pty Ltd manufactures a conveyor
idler roller
monitoring system, which is disclosed in PCT/AU2014/050246. As shown in figure
2, this
monitoring system comprises an idler roller 24 which is fitted with a sensor
26 that is located on
a shaft 28 inside the idler roller 24. A cable 30 connects the sensor 26 to an
external aerial 30 on
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a head 32 of the idler roller 24.
[0007] However, the problem with this monitoring system is that if that the
sensor 24 fails,
the entire idler roller 14 must be replaced. Alternatively, if the roller 10
fails, then the sensor 24
would be discarded with the roller 24. The installation of the aerial 30 and
internal sensor 26 also
complicates the manufacturing process of the idler roller 24, which makes it
more expensive.
Because idler rollers are ordered on mass by mining operators, a small
increase in the unit price
of each idler roller creates a substantial increase in the price of the
overall order.
[0008] It will be clearly understood that, if a prior art publication is
referred to herein, this
reference does not constitute an admission that the publication forms part of
the common general
knowledge in the art in Australia or in any other country.
OBJECT OF THE INVENTION
[0009] The object of the invention is to overcome or at least substantially
ameliorate the
aforementioned problems with the prior art
[0010] The present invention is directed to a monitoring assembly for a
conveyor idler
roller, which may at least partially overcome at least one of the
abovementioned disadvantages
or provide the consumer with a useful or commercial choice.
SUMMARY OF INVENTION
[0011] With the foregoing in view, the present invention in one form,
resides broadly in a
monitoring assembly for monitoring a conveyor idler roller, the conveyor idler
roller comprising
at least one end cap, the conveyor idler roller comprising:
= a labyrinth seal comprising an inner seal part configured to rotate with
the roller and an
outer seal part configured to remain stationary within the end cap when the
inner seal part
is rotating;
= a magnet mounted on the inner seal part; and
= a printed circuit board mounted on the outer seal part, the printed
circuit board
comprising:
o at least one sensor for sensing information from the conveyor idler
roller;
o a processor for recording the sensed information from the at least one
sensor; and
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o a communications device for transmitting and receiving information
between the
processor and an external user device.
[0012] In the present specification and claims (if any), the word
'comprising' and its
derivatives including 'comprises' and 'comprise' include each of the stated
integers but does not
exclude the inclusion of one or more further integers.
[0013] The monitoring assembly is mounted in the end cap of the conveyor
idler roller so
that the monitoring assembly can be retro-fitted to existing rollers by
exchanging the existing
end cap for one containing the monitoring assembly of the present invention.
Alternatively, the
monitoring assembly can be sold as part of a complete idler roller.
[0014] For the purposes of the specification, the term "labyrinth seal"
means a mechanical
seal which provides a tortuous path to help reduce ingress of dirt and/or
water into the idler roller
housing and bearing. The labyrinth seal may be selected from the group
consisting of; felt seal,
lip seal.
[0015] Preferably, the communications device is adapted to provide
information about the
assembly to a user. The information may include a global positioning system
location of the
assembly; installation information of the conveyor idler roller; a date of
installation of the
conveyor idler roller; an identity of the installer and/or a uniform resource
indicator (URI) to the
external device.
[0016] Preferably, the sensor is adapted to measure the rotational speed
and passage of the
magnet. The sensor also preferably includes an accelerometer mounted on the
outer part of the
seal for sensing vibrations in the conveyor idler roller. It is also preferred
that the assembly
includes a temperature sensor for measuring the temperature of the conveyor
idler roller. The
assembly may include a data concentrator for receiving signals from the
communications device
and transmitting those signals to a control centre. Preferably, the
communications device uses a
mesh wireless sensor network adapted to communicate with other processors in
other monitoring
assemblies.
[0017] Any of the features described herein can be combined in any
combination with any
one or more of the other features described herein within the scope of the
invention.
BRIEF DESCRIPTION OF DRAWINGS
[0018] Various embodiments of the invention will be described with
reference to the
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following drawings, in which:
[0019] Figure 1 is a perspective view of a conveyor for use with the
present invention.
[0020] Figure 2 is a perspective view of an idler roller fitted with a
prior art monitoring
assembly.
[0021] Figure 3 is side view of an idler roller monitoring system according
to an
embodiment of the present invention.
[0022] Figure 4 is a perspective view of the printed circuit board of the
idler monitoring
assembly of figure 3.
[0023] Figure 5 shows a representation of a user screen of an external user
device in
communication with a processor of the present invention.
[0024] Figure 6 shows the results of an electrical scattering simulation of
the present
invention fitted to a conveyor idler roller.
[0025] Figure 7 shows a graph of scattering parameter (S-parameters) versus
frequency
(GHz) of the simulation shown in Figure 6 (S-parameters magnitude (S-parameter
= S1,1) ¨
V12).
DETAILED DESCRIPTION
[0026] The monitoring assembly 32 of the present invention is shown in
Figures 3 and 4.
The monitoring assembly 32 is used on a conveyor idler roller 34 which may
have a shaft 36.
However, without departing from the present invention, the monitoring assembly
32 may also be
used with a shaft-less conveyer idler roller comprising a pair of roller head
assemblies, one at
each end of a roller housing (not shown). The idler roller 34 has a labyrinth
seal with an inner
part 38 and outer part 40 enclosed in an end cap 24.
[0027] A magnet 42 is mounted in the inner part 38 of the labyrinth seal (a
series of magnets
may be used). A sensor 44 for measuring the rotation of the magnet 42 is
mounted on a printed
circuit board 25 attached to the outer part 22 of the seal 18. Also mounted on
the printed circuit
board 25 is a processor 46. The processor 46 has the ability to record
information from the
sensor 44.
[0028] The assembly 32 has a communications device 48 (in the form of a 2.4
GHz antenna)
mounted on the printed circuit board 25 for transmitting and receiving
information between the
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processor 46 and an external device 49 such as a tablet computer or smart
telephone running iOS
or Android operating system (shown in figure 1). The communications device 48
acts as a radio
network node and connects to a mesh network, which is preferably a BluetoothTM
network.
However, any suitable network may be used, for example WiFiTM, ANTTm or
another proprietary
network standard.
[0029] The assembly 32 also includes an accelerometer 50 mounted on the
printed circuit
board 25. The accelerometer 50 senses vibrations in the conveyor idler roller
16. The vibrations
can indicate whether the conveyor idler roller has a problem, such as a
bearing breaking up, the
roller fracturing, or an end cap becoming detached from the roller. The
assembly 10 includes a
temperature sensor 52 mounted on the printed circuit board 25 for measuring
the temperature of
the conveyor idler roller 12. A high temperature could indicate that there
will be an imminent
failure of the bearing failure. In addition, the assembly 32 also includes an
electrically erasable
programmable read-only memory (EEPROM) 54 SPI serial that contains 131072
bytes of data, is
used to store long term (persistent) data for that idler roller (company,
conveyor, frame, carry or
return roller, etc). It will also contain a circular buffer of recent
information that pertains to the
roller's current state. Its use is to save operational data whilst the unit is
powered down. This
operational data would be used for maintenance or warranty actions.
[0030] The communications device 48 connects to a data concentrator 56 (see
figure 1).
Data concentrators are positioned approximately every fifty meters along the
conveyor belt 12.
The data concentrators 56 relay signals from the monitoring assemblies 32 on
each conveyor
idler roller 34 to a central control centre 58 and/or to the external device
49. The mesh network
may exhibit self-healing properties and automatically uses alternate routes in
the event that an
idler roller failure or a low radio link quality due to high bit error rates
or low radio signal
strength.
[0031] The external device 49 runs a software application for interacting
with the
assemblies 32. The software application represents various conveyor idler
rollers and illustrates
which rollers are functioning and which rollers are malfunctioning. A
technician is thereby able
to readily identify the defective roller. The software application provides
information regarding
the temperature of the conveyor idler roller. A high temperature may indicate
that a bearing is
about to fail. The software application can also indicate whether the conveyor
idler roller is
vibrating in an abnormal manner, compared to the other rollers nearby. This
may indicate that
the roller has failed.
[0032] The communications device 48 can transmit information via
BluetoothTM low energy
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technology (BLE) as a beacon. A Generic Attributes (GATT) protocol is built on
top of the BLE
and defines how the processor 46 and the external deice 49 transmits and
receives information
between each other. As part of the protocol for all beacons and all other
BluetoothTM devices,
each assembly will transmit a randomly generated universally unique identifier
(UUID; Version
4 or above) or globally unique identifier (GUID).
[0033] Alternatively, each assembly can transmit packets of data including
a unit identifier
packet, a universal resource locator packet, and four different telemetry
frames. The frames use
standard EddystoneTM data (which is based on the iBeaconTM produced and sold
by Apple Inc). The
first telemetry frame contains details of the battery voltage, the
temperature, the number of
advertisements and the running count (in tenths of a second). The second
telemetry frame
contains information such as the installation date, the vibration level in g-
force, the conveyor
frame number, operating hours, belt speed and bearing lifespan. A malfunction
warning can be
generated if vibration level or temperature is above predefined limits. The
third telemetry frame
contains a code which identifies the manufacturer of the assembly, the
employee number of the
customer installing the assembly, the assembly serial number, the
manufacturing date, and the
date the assembly was received on site. The fourth telemetry frame contains
the assembly
firmware version and the bearing life hours left. These telemetry frames can
be encrypted if
required.
[0034] The idler roller information such as operating hours can be used to
determine
warranty claims if failure is seen before a predetermined operating time span
(e.g. 250,000 hours
rather than time span).
[0035] The communications device 48 uses its near field communications
capability to
update the running firmware on the assembly 10. The external device 49 can be
used to record
program information into the assembly 10. This information includes conveyor
number, frame
number, roller identifier number, information identifying whether the roller
is a carrier or a
return roller, alerts if the idler roller should be changed out, the date of
installation and the
employee number.
[0036] Figure 5 shows a worker using an external device receiving
information from a roller
on a conveyor that is reporting problems, after an inspection of the data and
the roller, the worker
would then to mark the roller for change out. The conveyor number, frame
number, and roller
number (shown as Module in this occasion), along with the information if it
was a Carry or
Return roller. This would be validated by the worker, and the sites roller
application database
would be updated, to start the sites roller replacement procedure.
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[0037] In this way, the present invention provides for improved predictive
maintenance of a
conveyor idler roller through real time monitoring. These rollers can be
connected to via any
number of devices to check for problems so that they can be addressed more
efficiently. Real
time data monitoring data from the processor 46 may utilise augmented reality
to improve
visualisation to a user. In this situation the user external device may be a
pair of mixed reality
smartglasses such as MicrosoftTM HoloLensTM. Tapping on a roller, broken or
working, will
display information about that roller. Tapping a on broken roller will include
the option to go
through the steps for how to fix, including a visual representation of the
steps.
[0038] An advantage of the assembly of the present invention is that it can
be easily
retrofitted to existing conveyor idler rollers. The end cap of a conventional
conveyor idler roller
can be removed and replaced with the assembly. If a conveyor idler roller
fails, then the
assembly can be removed (if required) and used on another conventional
conveyor idler roller.
[0039] Having thus described the invention in detail, it should be apparent
that various
modifications and changes can be made without departing from the spirit and
scope of the
present invention. For example, the processor 46 may have a near field
communications
receiver/transmitter and/or transmitter/receivers that can run both the ANTTm
and BluetoothTM
protocols at the same time. The separate components of the printed circuit
board 25 may be
combined into single components without departing from the scope of the
present invention. For
example, the accelerometer 50 may be combined with the temperature sensor 52
in the same
component. The processor 46 may also act as temperature sensor 52 as it has an
in-built
temperature sensor. Consequently, these and other modifications are
contemplated to be within
the spirit and scope of the claims.
Working Example 1: Electrical Scattering simulation
[0040] Figures 6 and 7 show the expected radio frequency (RF) radiation
pattern for the
antenna shown in Figure 4. The various colours in the three dimensional signal
strength graph in
Figure 6 represents the varying signal strengths and directions that the RF
signal is being
transmitted. Figure 7 shows the same RF radiation pattern in 2 dimensions.
[0041] Thus the present invention has a number of advantages over the prior
art such as:
= Real time monitoring of a conveyer idler roller for predictive
maintenance;
= Improved ease of use by retrofitting to an existing conveyer idler
roller;
= Improved ease of use by programmability to upgrade firmware periodically;
= Reducing conveyer idler roller downtime thereby saving on costly lost
production to
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boost productivity;
= Reducing the need for costly physical inspection;
= Secure communication using authorised devices.
= Low energy consumption (e.g. with the use of Bluetooth Low Energy (BLE)
technology).
[0042] Reference throughout this specification to 'one embodiment' or 'an
embodiment'
means that a particular feature, structure, or characteristic described in
connection with the
embodiment is included in at least one embodiment of the present invention.
Thus, the
appearance of the phrases 'in one embodiment' or 'in an embodiment' in various
places
throughout this specification are not necessarily all referring to the same
embodiment.
Furthermore, the particular features, structures, or characteristics may be
combined in any
suitable manner in one or more combinations.
[0043] In compliance with the statute, the invention has been described in
language more or
less specific to structural or methodical features. It is to be understood
that the invention is not
limited to specific features shown or described since the means herein
described comprises
preferred forms of putting the invention into effect. The invention is,
therefore, claimed in any
of its forms or modifications within the proper scope of the appended claims
(if any)
appropriately interpreted by those skilled in the art.
