A conveyor system that includes a sprocket, a conveyor element, a sensor, a tensioning system, and an electronic processor. The conveyor element is coupled to the sprocket to move around the sprocket. The sensor is positioned adjacent to the sprocket and configured to generate an output signal indicative of a detection of the conveyor element. The electronic processor is coupled to the sensor and to the tensioning system. The electronic processor is configured to receive the output signal from the sensor, estimate a trajectory of the conveyor element based on the output signal, determine a value for slack distance based on the estimated trajectory of the conveyor element, and control the tensioning system based on the value for slack distance.

A system for detecting a rip in a conveyor belt carrying a material, the system including: a sensor arrangement configured to provide a light curtain under at least a portion the conveyor belt to detect material passing through the rip thereby detecting the rip. A related method is also disclosed.

A system for detecting a rip in a conveyor belt carrying a material, the system including: a sensor arrangement configured to provide a light curtain under at least a portion the conveyor belt to detect material passing through the rip thereby detecting the rip. A related method is also disclosed.

A conveyor system includes a rail that supports multiple carts that move along a track of the conveyor system. A plurality of sensors is operably connected to the rail and configured to measure vibrations of the rail as the carts move along the track. One or more sensors are operably connected to the cart and configured to take measurements of the cart as the cart moves along the track. A central controller collects data from sensors, and a processor analyzes the data to determine whether the data is within a predetermined range that corresponds to normal operation of the conveyor system. A method of operating the conveyor system includes moving the multiple carts along the rail and collecting data from the sensors. The data is analyzed to determine if it is within a predetermined range.

A conveyor system includes a rail that supports multiple carts that move along a track of the conveyor system. A plurality of sensors is operably connected to the rail and configured to measure vibrations of the rail as the carts move along the track. One or more sensors are operably connected to the cart and configured to take measurements of the cart as the cart moves along the track. A central controller collects data from sensors, and a processor analyzes the data to determine whether the data is within a predetermined range that corresponds to normal operation of the conveyor system. A method of operating the conveyor system includes moving the multiple carts along the rail and collecting data from the sensors. The data is analyzed to determine if it is within a predetermined range.

A method includes emitting a laser including a plurality of laser points onto a surface of a conveyor belt, capturing a plurality of first images of the surface of the conveyor belt during a first cycle of the conveyor belt, creating a first three-dimensional image of the surface of the conveyor belt during the first cycle, each of a plurality of locations of the surface of the conveyor belt in the first three-dimensional image being assigned first position data, capturing a plurality of second images of the surface of the conveyor belt during a second cycle of the conveyor belt; creating a second three-dimensional image of the surface during the second cycle, each of the plurality of locations of the surface in the second three-dimensional image being assigned second position data; and determining whether a difference between the first and second position data exceeds a predetermined threshold.

A method includes emitting a laser including a plurality of laser points onto a surface of a conveyor belt, capturing a plurality of first images of the surface of the conveyor belt during a first cycle of the conveyor belt, creating a first three-dimensional image of the surface of the conveyor belt during the first cycle, each of a plurality of locations of the surface of the conveyor belt in the first three-dimensional image being assigned first position data, capturing a plurality of second images of the surface of the conveyor belt during a second cycle of the conveyor belt; creating a second three-dimensional image of the surface during the second cycle, each of the plurality of locations of the surface in the second three-dimensional image being assigned second position data; and determining whether a difference between the first and second position data exceeds a predetermined threshold.

Conveyor idler monitoring apparatus, systems and methods are provided. In some embodiments, one or more sensors (e.g., temperature sensors, load sensors, etc.) are supported by the shaft of a conveyor idler. In some embodiments, one or more sensors are in data communication with a wireless transmitter. In some embodiments, a power generator driven by rotation of the idler is in electrical communication with one or more sensors and/or a wireless transmitter. In some embodiments, a plurality of idlers monitoring systems are in data communication with a conveyor monitoring system and/or operational monitoring system.

Conveyor idler monitoring apparatus, systems and methods are provided. In some embodiments, one or more sensors (e.g., temperature sensors, load sensors, etc.) are supported by the shaft of a conveyor idler. In some embodiments, one or more sensors are in data communication with a wireless transmitter. In some embodiments, a power generator driven by rotation of the idler is in electrical communication with one or more sensors and/or a wireless transmitter. In some embodiments, a plurality of idlers monitoring systems are in data communication with a conveyor monitoring system and/or operational monitoring system.

To determine, with high accuracy, whether an anomaly has occurred in equipment to be monitored, an anomaly detection apparatus includes an acquisition unit and a determination unit. The determination unit acquires detection result information indicating a detection result of a vibration sensor attached to equipment including a movable unit. The determination unit determines, by using the detection result information, presence or absence of an anomaly of the equipment. The detection result information includes a magnitude of a vibration of each of a plurality of axes oriented in directions different from each other. The determination unit computes, with respect to each of the plurality of axes, a difference between a magnitude of a vibration at a target timing, and a magnitude of a vibration at a predetermined period of time before the target timing or a criterion value previously set. Then, the determination unit determines, when the difference exceeds a criterion in any of the axes, that an anomaly is occurring in the equipment at the target timing.