Chain Monitoring System
20180162651 ยท 2018-06-14
Inventors
Cpc classification
B65G43/06
PERFORMING OPERATIONS; TRANSPORTING
A21B1/46
HUMAN NECESSITIES
B65G17/385
PERFORMING OPERATIONS; TRANSPORTING
B65G2203/0283
PERFORMING OPERATIONS; TRANSPORTING
B65G43/02
PERFORMING OPERATIONS; TRANSPORTING
B65G17/48
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65G43/06
PERFORMING OPERATIONS; TRANSPORTING
B65G17/48
PERFORMING OPERATIONS; TRANSPORTING
A21B1/46
HUMAN NECESSITIES
Abstract
A monitoring and feedback system may provide real-time feedback on the bearings in the chain of a proofer/oven conveyor system. The system may detect a bearing seizure before any damage can occur to the track and/or may provide for improper lubrication detection. Accordingly, a chain section or a bearing may be pulled out of the conveyor system for repair/replacement, thereby prolonging the life of the conveyor system as a whole, including the conveyor chain and bearings.
Claims
1. A chain monitoring system comprising: a conveyor arranged to move from an upstream position to a downstream position; and a chain provided along the conveyor, the chain separated into a plurality of chain sections, wherein each of the plurality of chain sections is capable of being removed from the chain.
2. The system of claim 1 further comprising: a plurality of pitches provided along the conveyor, wherein each of the plurality of pitches contains a horizontal bearing and a set of two vertical bearings.
3. The system of claim 2, wherein the horizontal bearing is arranged toward the center of each of the plurality of pitches, and wherein the set of two vertical bearings are arranged on a trailing side of each of the plurality of pitches.
4. The system of claim 2, wherein each of the plurality of pitches is capable of being removed from the conveyor after a starting pitch is jogged to a maintenance position.
5. The system of claim 2, wherein any of the horizontal bearing and the set of two vertical bearings is capable of being removed from the conveyor.
6. The system of claim 2 further comprising: a flag assembly provided on the conveyor, wherein the flag assembly indicates whether any of the horizontal bearing and the set of two vertical bearings requires maintenance or replacement.
7. The system of claim 2 further comprising: a first array of thermocouples for the horizontal bearing, and a second and a third array of thermocouples for the set of two vertical bearings arranged downstream of a lubrication system, wherein thermal trends of each bearing are monitored and tracked.
8. The system of claim 1 further comprising: at least one upstream horizontal thermocouple arranged downstream of at least one upstream vertical thermocouple; an oiler arranged downstream of the at least one upstream horizontal thermocouple and the at least one upstream vertical thermocouple; and a home sensor arranged downstream of the oiler.
9. The system of claim 7 further comprising: a maintenance module arranged downstream of the home sensor; at least one downstream horizontal thermocouple arranged downstream of the maintenance module; and at least one downstream vertical thermocouple arranged downstream of the at least one downstream horizontal thermocouple.
10. The system of claim 1 further comprising: a plurality of interactive display screens including a home screen, a trends screen, a sensors screen, an active chain screen, and an alarms screen.
11. The system of claim 10, wherein the plurality of interactive display screens provide real-time data on bearing temperatures, pitch temperatures, and maintenance alarms.
12. A conveyor system, comprising: a conveyor arranged to move from an upstream position to a downstream position; a proofer or an oven including a load-on position and a load-off position, wherein the load-on position is the starting point for the conveyor and the load-off position is the ending point; and a chain provided along the conveyor, the chain separated into a plurality of chain sections, wherein each of the plurality of chain sections is capable of being removed from the chain.
13. The system of claim 12 further comprising: a plurality of pitches provided along the conveyor, wherein each of the plurality of pitches contains a horizontal bearing and a set of two vertical bearings.
14. The system of claim 13, wherein the horizontal bearing is arranged toward the center of each of the plurality of pitches, and wherein the set of two vertical bearings are arranged on a trailing side of each of the plurality of pitches.
15. The system of claim 13 further comprising: a feedback mechanism arranged to continuously monitor thermal trends of any of the horizontal bearing and the set of two vertical bearings and compare upstream and downstream data.
16. The system of claim 13, wherein each of the plurality of pitches is capable of being removed from the conveyor after a starting pitch is jogged to a maintenance position.
17. The system of claim 13, wherein any of the horizontal bearing and the set of two vertical bearings is capable of being removed from the conveyor.
18. The system of claim 12 further comprising: a plurality of thermocouples positioned along the conveyor and arranged to measure a temperature at various points on the conveyor.
19. The system of claim 18, wherein a temperature change of approximately 0.2 second at any thermocouple results in a flag being displayed to service the system.
20. The system of claim 12 further comprising: a plurality of interactive display screens including a home screen, a trends screen, a sensors screen, an active chain screen, and an alarms screen.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION
[0027] Embodiments of the present disclosure may provide monitoring and feedback in a proofer/oven conveyor system. Embodiments of the present disclosure may provide real-time feedback as to the bearings of a conveyor chain that assists in movement along the track of the conveyor system. Embodiments of the present disclosure may detect a bearing seizure before any damage can occur to the track. Additional embodiments of the present disclosure also may provide for improper lubrication detection. Accordingly, a chain section and/or a bearing may be removed from the conveyor system for repair/replacement, thereby prolonging the life of the conveyor system as a whole, including the conveyor chain and bearings.
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[0030] Conveyor system 100A, 100B, 100C may be formed in a loop-like shape having curved portions. Examples of those curved portions according to an embodiment of the present disclosure are depicted in
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[0032] Conveyor system 100A, 100B, 100C also may include a flag assembly according to embodiments of the present disclosure. This flag assembly may be provided on the straight portion of conveyor system 100A, 100B, and 100C, as depicted in
[0033] FIGURE IF depicts proofer/oven 100F according to an embodiment of the present disclosure. Proofer/oven 100F load-on position 110 may provide a starting point for conveyor 100A, 100B, and 100C and proofer/oven 100F load-off position 120 may provide an end point for conveyor system 100A, 100B, and 100C. Load-on position 110 and load-off position 120 may include plurality of T/Cs 140A (
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[0036] It should be appreciated that embodiments of the present disclosure may provide a feedback mechanism for oven/proofer conveyor systems that may provide real-time feedback on bearings in the chains. Such a mechanism may allow for both seized bearing detection and/or improper lubrication detection.
[0037] With respect to seized bearing detection, when a seized bearing crosses the T/C array, it may create a thermal ripple effect of significantly greater amplitude than a rolling bearing. Once detected, an incident timer may be initiated. Using the speed and length of the chain, the feedback mechanism may define a target time window for successive repeat occurrences. If the occurrence repeats within the expected time window on two successive round trips, then the feedback mechanism may provide an alert/alarm but continue to run. Multiple concurrent incidents may then be monitored with mutually exclusive incident timers. It should be appreciated that each T/C array may act independently of the other arrays, allowing the feedback mechanism to quickly direct the operator to the exact location of the target bearing. Logic can be included within the system according to some embodiments of the present disclosure that may command the system to stop the target bearing at a desired location, such as an inspection station.
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[0039] By having such a system, when high temperatures are detected (indicating dragging), the oven/proofer conveyor track can be stopped, and a chain section can be pulled out for replacement. Thus, embodiments of the present disclosure may provide a passive system to alert of bad bearings so that they may be changed one at a time. In other embodiments of the present disclosure, all of the bad bearings may be replaced all in one cycle. This also may prolong the life of a bearing within a chain system.
[0040] While embodiments of the present disclosure have been described as providing a passive system, it should be appreciated that in some embodiments of the present disclosure, the system may be an active system that may allow the user (such as a bakery operator) to index a seized bearing and may be immediately replaced within a short period of time. In some embodiments of the present disclosure, this replacement may be performed within approximately 30 seconds while the equipment remains in operation.
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[0044] It should be appreciated that in some embodiments of the present disclosure, a quantity of pitches in the conveyor system may be automatically detected. To detect the quantity of pitches, a home flag may be installed at a first pitch and may pass a proximity switch and home sensor. It should be appreciated that debris and loose parts may cause readings to be incorrect and/or false flags to be detected. It should be appreciated that when the home sensor is functioning properly and false flags are resolved, the chain monitoring system or chain may be scanned to detect the quantity of pitches using a button on a maintenance screen. It should be appreciated that a programmable logic controller (PLC) may begin a pitch scan routine and may wait for the home flag to pass the home sensor. It should further be appreciated that when the flag passes the home sensor, a counter may count every pitch until another flag passes the home sensor again in some embodiments of the present disclosure.
[0045] It should be appreciated that in some embodiments of the present disclosure, a home screen may provide an overview of the chain monitoring system. It should be appreciated that the home screen may include a process temperature display that may provide the operating temperature of the oven or proofer. It should also be appreciated that the home screen may provide a bearing status box that may provide a user with an overview of bearing positions and a total number of sick or malfunctioning bearings that may be detected in the system. It should further be appreciated that average and high temperatures that may be read by each thermocouple position may be displayed. It should be appreciated that the home screen may provide a lubrication overview that may display a quantity of oil cycles and an average oil cycle duration for a selected day and/or week. It should also be appreciated that the home screen may provide a sensor overview that may display a quantity of sick or malfunctioning thermocouples in which the temperature may vary greatly from other thermocouples in the chain monitoring system. It should further be appreciated that the home screen may provide a navigator tool bar.
[0046] It should be appreciated that in some embodiments of the present disclosure, a trends screen may display a temperature history for each set of thermocouples in the chain monitoring system. It should be appreciated that in some embodiments of the present disclosure, a sensors screen may display a temperature and health reading of each sensor in the chain monitoring system. It should be appreciated that a sick or malfunctioning sensor may automatically be reset if its reading is within an acceptable deviation from an average of the remaining thermocouples in the chain monitoring system. It should be appreciated that a temperature difference between two sensors in a pair may be monitored. If a temperature of one thermocouple is less than the temperature of the other thermocouple, then the thermocouple with the lower temperature may be determined to have loosened from the track and may not be in contact with the chain monitoring system. An alarm may be triggered to alert the user of a loose thermocouple.
[0047] It should be appreciated that in some embodiments of the present disclosure, an active chain screen may be provided to allow a user to navigate to any bearing in the active chain. It should be appreciated that only the number of bearings available in the active system may appear on the active chain screen. It should also be appreciated that there may be more pitches utilized in the chain monitoring system than can fit on the active chain screen, and additional active chain screen navigation buttons may provide a user with access to the remaining pitches. It should be appreciated that the active chain screen and/or a bearing alarm screen may display a list of pitches, the temperature for each bearing on each pitch, a flag count which may indicate the number of times that each bearing may have a high temperature trigger, and service information that may indicate the number of times each bearing may have been cleaned in place in the system and/or cleaned out of place. It should be appreciated that a bearing storage and a chain segment menu may be provided and each menu may provide pitch, identification, and service information.
[0048] It should be appreciated that in some embodiments of the present disclosure, a maintenance screen may be provided and may allow a user to make changes to configurations of the chain monitoring system. It should be appreciated that the maintenance screen may display offsets that may allow the user to set locations of thermocouple arrays. It should further be appreciated that vertical and horizontal change in temperature values may be displayed and may set a temperature change threshold for detecting and flagging a seized bearing. It should also be appreciated that a temperature change of approximately 0.2 seconds at any selected thermocouple may result in a high temperature flag being displayed. The maintenance screen may also provide information regarding an amount of time that the system may wait after switching between primary and secondary thermocouples before looking for high temperature flags again to prevent false flags during switching. A loose thermocouple alarm and a temperature difference for determining a loose thermocouple may be provided. An amount of time that a thermocouple may be out of an acceptable temperature range before an alarm is triggered may be provided. A jog speed at which the system may request for the oven or proofer PLC to jog the system may be provided. High and low temperature values for each bearing may be provided and may be reset. A reset chain button may enable an automated scan function and may count every pitch in the conveyor to determine a total number of pitches for track bearings. A jog to bearing button may be provided that may allow the user to jog any bearing.
[0049] It should be appreciated that in some embodiments of the present disclosure, a bearings alarm screen may be provided. It should be appreciated that when a bearing is flagged, an alarm may be displayed, and a user may access details regarding the alarm. It should also be appreciated that the bearings alarm screen may allow the user to make a selection regarding jogging the system, cleaning bearings in place or out of place, and retiring bearings among other actions.
[0050] Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.