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, idler 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, idler monitoring systems are in data communication with a conveyor monitoring system and/or operational monitoring system.

A troughing idler assembly for a bulk material belt conveyor is disclosed having a frame, at least four axles, and at least four wheels. The axles are mounted to the frame, each of the axles extending in a common plane or at least one plane transverse to a conveying direction. Each wheel is mounted to a corresponding axle. The wheels are arranged in a trough configuration where at least two outer wheels of are positioned vertically higher than at least one inner wheel. A return idler assembly for a bulk material belt conveyor is disclosed having an axle and a plurality of wheels. A bulk material belt conveyor is disclosed having the troughing idler assembly and/or the return idler assembly.

A troughing idler assembly for a bulk material belt conveyor is disclosed having a frame, at least four axles, and at least four wheels. The axles are mounted to the frame, each of the axles extending in a common plane or at least one plane transverse to a conveying direction. Each wheel is mounted to a corresponding axle. The wheels are arranged in a trough configuration where at least two outer wheels of are positioned vertically higher than at least one inner wheel. A return idler assembly for a bulk material belt conveyor is disclosed having an axle and a plurality of wheels. A bulk material belt conveyor is disclosed having the troughing idler assembly and/or the return idler assembly.

A conveyor system is configured to prevent objects from getting caught or pinched between rollers and belts. The system includes a base, frames on opposite sides of the base, a plurality of rollers each having a bearing, an attachment axle, a drive shaft, a drive belt connecting the draft shaft to one of the bearings, and connecting belts connecting the bearings. The bearings may be disposed between the frames such that the drive belt and connecting belts are protected between the frames or may be disposed within the frames such that the drive belt and connecting belts are protected within the frame when a cover is attached to the frame.

A conveyor system is configured to prevent objects from getting caught or pinched between rollers and belts. The system includes a base, frames on opposite sides of the base, a plurality of rollers each having a bearing, an attachment axle, a drive shaft, a drive belt connecting the draft shaft to one of the bearings, and connecting belts connecting the bearings. The bearings may be disposed between the frames such that the drive belt and connecting belts are protected between the frames or may be disposed within the frames such that the drive belt and connecting belts are protected within the frame when a cover is attached to the frame.

An end cap assembly for a conveyor roll includes an end cap configured to fit over an end of the conveyor roll, and the end cap has an opening. The end cap assembly further includes a spring member configured to be positioned between the end of the conveyor roll and the end cap, and a fastener that is insertable into the opening of the end cap. The fastener is configured to cooperate with the spring member to apply a retention force to assist in retaining the end cap on the conveyor roll.

An end cap assembly for a conveyor roll includes an end cap configured to fit over an end of the conveyor roll, and the end cap has an opening. The end cap assembly further includes a spring member configured to be positioned between the end of the conveyor roll and the end cap, and a fastener that is insertable into the opening of the end cap. The fastener is configured to cooperate with the spring member to apply a retention force to assist in retaining the end cap on the conveyor roll.

A brake mechanism for a brake caster is disclosed. In various embodiments, the brake mechanism includes a roller cylinder having a hollow interior and an inner cylindrical surface; a brake shaft disposed within the hollow interior of the roller cylinder and having an outer cylindrical surface; a piezoelectric disk disposed within the hollow interior of the roller cylinder; and a rotor disk disposed adjacent the piezoelectric disk.

A brake mechanism for a brake caster is disclosed. In various embodiments, the brake mechanism includes a roller cylinder having a hollow interior and an inner cylindrical surface; a brake shaft disposed within the hollow interior of the roller cylinder and having an outer cylindrical surface; a piezoelectric disk disposed within the hollow interior of the roller cylinder; and a rotor disk disposed adjacent the piezoelectric disk.