CONVEYOR IDLER MONITORING APPARATUS, SYSTEMS, AND METHODS

Abstract

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.

Claims

1. A conveyor monitoring system comprising: a plurality of conveyor idlers, each conveyor idler including a shaft configured to be supported on a conveyor, a cylinder rollingly supported on the shaft and configured to at least partially support a conveyor belt, and a monitoring system at least partially supported on the shaft, the monitoring system including a temperature sensor, a vibration sensor mounted to the shaft, and a wireless transmitter in data communication with the temperature sensor and the vibration sensor, the monitoring system configured to generate idler-related measurements including temperature data from the temperature sensor and vibration data from the vibration sensor; a communication gateway in wireless data communication with the wireless transmitters of the plurality of conveyor idlers; and an application server in data communication with the communication gateway, the application server configured to receive the idler-related measurements from the plurality of conveyor idlers and to apply artificial intelligence to the idler-related measurements including the vibration data to identify which idler among the plurality of idlers will fail first based on the vibration data and on the AI-processed temperature data.

2. The conveyor monitoring system of claim 1, wherein the temperature sensor includes a bearing temperature sensor at least partially received in a cavity in a radially outer surface of the shaft adjacent to a bearing supporting the cylinder on the shaft.

3. The conveyor monitoring system of claim 1, wherein the monitoring system further includes a cylinder temperature sensor configured to detect a temperature of an inner surface of the cylinder.

4. The conveyor monitoring system of claim 3, wherein the cylinder temperature sensor comprises an infrared temperature sensor oriented toward the inner surface of the cylinder.

5. The conveyor monitoring system of claim 1, wherein the vibration sensor comprises a noise sensor in contact with a bearing supporting the cylinder on the shaft.

6. The conveyor monitoring system of claim 1, wherein the monitoring system further includes a rotation sensor configured to detect a rotational speed of the cylinder.

7. The conveyor monitoring system of claim 6, wherein the application server is further configured to compare the rotational speed of the cylinder to a belt speed to estimate a current cylinder diameter and a cylinder wear percentage.

8. The conveyor monitoring system of claim 1, wherein the monitoring system further includes an energy generator configured to generate power from rotation of the cylinder about the shaft, the energy generator comprising an inner ring supported on the shaft and an outer ring supported in the cylinder, with a plurality of magnets in one of the inner ring or the outer ring and a plurality of electromagnetic coils in the other.

9. The conveyor monitoring system of claim 1, wherein the artificial intelligence comprises machine learning or a neural network.

10. The conveyor monitoring system of claim 2, wherein the vibration sensor comprises a noise sensor in contact with a bearing supporting the cylinder on the shaft.

11. A method of monitoring and predicting failure in a conveyor system, the method comprising: providing a plurality of conveyor idlers on the conveyor system, each conveyor idler including a shaft supported on the conveyor system, a cylinder rollingly supported on the shaft and at least partially supporting a conveyor belt, and a monitoring system at least partially supported on the shaft, the monitoring system including a temperature sensor, a vibration sensor mounted to the shaft, and a wireless transmitter; generating, with the monitoring system of each conveyor idler, idler-related measurements including temperature data from the temperature sensor and vibration data from the vibration sensor; transmitting the idler-related measurements wirelessly from the wireless transmitters to a communication gateway; receiving the idler-related measurements at an application server in data communication with the communication gateway; and applying, at the application server, artificial intelligence to the idler-related measurements including the vibration data to identify which idler among the plurality of idlers will fail first based on the temperature data and AI-processed vibration data.

12. The method of claim 11, further comprising detecting, with a cylinder temperature sensor of the monitoring system, a temperature of an inner surface of the cylinder, wherein the idler-related measurements include the temperature of the inner surface of the cylinder.

13. The method of claim 11, further comprising detecting, with a rotation sensor of the monitoring system, a rotational speed of the cylinder, wherein the idler-related measurements include the rotational speed of the cylinder.

14. The method of claim 13, further comprising comparing, at the application server, the rotational speed of the cylinder to a belt speed to estimate a current cylinder diameter and a cylinder wear percentage.

15. The method of claim 11, wherein the temperature sensor includes a bearing temperature sensor at least partially received in a cavity in a radially outer surface of the shaft adjacent to a bearing supporting the cylinder on the shaft.

16. A method of predicting failure of conveyor idlers in a conveyor monitoring system, the method comprising: receiving, at an application server, idler-related measurements from a plurality of conveyor idlers via a communication gateway, each conveyor idler including a shaft supported on a conveyor, a cylinder rollingly supported on the shaft and configured to at least partially support a conveyor belt, and a monitoring system at least partially supported on the shaft and including a temperature sensor, a vibration sensor mounted to the shaft, and a wireless transmitter configured to transmit the idler-related measurements including temperature data from the temperature sensor and vibration data from the vibration sensor; processing the idler-related measurements at the application server; and applying an artificial intelligence at the application server to the processed idler-related measurements including the vibration data to identify which idler among the plurality of idlers will fail first based on the temperature data AI-processed vibration data.

17. The method of claim 16, wherein the idler-related measurements further include a rotational speed of the cylinder detected by a rotation sensor of the monitoring system.

18. The method of claim 17, further comprising determining, using the artificial intelligence, an existing idler failure based on a comparison of the rotational speed of the cylinder to a belt speed.

19. The method of claim 16, wherein the idler-related measurements further include a bearing temperature from a bearing temperature sensor at least partially received in a cavity in the shaft adjacent to a bearing.

20. The method of claim 16, further comprising displaying, on a user interface in data communication with the application server, an indication of which idler among the plurality of idlers will fail first.

Description

DESCRIPTION

[0016] Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIGS. 1 and 2 illustrate an embodiment of a conveyor idler 100. The conveyor idler 100 includes a cylinder 130 rollingly supported on a shaft 200. The shaft 200 is supported (e.g., in a stationary manner) on a conveyor. The cylinder 130 is configured to at least partially support a conveyor belt B.

[0017] The idler 100 optionally includes end discs 140-1, 140-2 disposed at opposing ends of the shaft 200 and mounted to opposing ends 220-1, 220-2 of the cylinder 130. Each end disc is optionally supported on an associated bearing 160 (e.g., ball bearing). A seal assembly 150 is optionally disposed outboard of each bearing assembly to at least partially prevent external liquid and/or debris from entering an interior volume of the idler 100.

[0018] Referring to FIG. 2, a monitoring system 600 (e.g., one of the monitoring system embodiments described herein) is optionally at least partially supported on the shaft 200.

[0019] Referring to FIGS. 3 and 4, one or more mounting boards 260, 262 are optionally mounted to the shaft 200 for supporting one or more electronic components of the monitoring system 600. In some embodiments, a load sensor 500 is supported on (e.g., mounted to the shaft 200). In some embodiments, a cavity 250 is provided in an end 220 of the shaft 200 for housing a transmitter and/or other components of the monitoring system. An opening 230 is optionally provided in the shaft for at least partially receiving one or more electrical connectors (e.g., wire, cable, etc.) which optionally connect the transmitter to the load sensor 500 and/or other components supported on the shaft 200 (e.g., on mounting board 260). In some embodiments, a transmitter is at least partially received in the cavity 250. In alternative embodiments, a cavity 250 may be omitted and the transmitter is optionally mounted on the end 220 of the shaft or elsewhere on the idler and/or conveyor.

[0020] In some embodiments, one or more cavities 240 are provided adjacent to (e.g., radially inward of) the bearing 160. In some embodiments, each cavity 240 is provided in a radially outer surface of the shaft 200. In some embodiments, a temperature sensor 635 (e.g., resistance temperature detector, thermocouple, etc.) is at least partially received in one or more cavities 240.

[0021] Referring to FIG. 5, an embodiment of a load sensor 500 is illustrated. The load sensor 500 optionally includes a deflector arm 510. One or more strain gauges 550 are optionally mounted to the deflector arm (e.g., in a Wheatstone bridge or other arrangement). The deflector arm 510 is optionally mounted to the shaft 200 (e.g., an upper surface of the shaft, disposed between the shaft and the conveyor belt, etc.) such as by one or more bolts 512. The deflector arm 510 is optionally spaced apart (e.g., vertically spaced apart) from the shaft 200 by a spacer 520. A bolt 514 or other apparatus optionally applies a load between the deflector arm 510 and the shaft 200. A rounded lower surface 530 (e.g., a ball) optionally at least partially transfers a load between the deflector arm 510 and the shaft 200. The bolt 514 is optionally adjustable in order to increase or decrease the load on the lower surface 530. The rounded lower surface 530 is optionally located at or near an axial midpoint of the shaft 200 (e.g., at or near a location equidistant to the ends 220-1, 220-2). Deflection of the shaft 200 optionally changes a deflection of the deflector arm 510 such that one or more strain gauges 550 generate a modified strain signal related to the amount of deflection of the shaft 200.

[0022] Referring to FIG. 6, an embodiment of a monitoring system 600 is schematically illustrated. The load sensor 500 (e.g., a load cell and/or strain gauge thereof) is optionally in data communication with a processor 625 (e.g., optionally via an amplifier 640 which is optionally configured to convert an analog signal to a digital signal). One or more temperature sensors 635 are optionally in data communication with the processor 625. A vibration sensor 620 (e.g., optionally mounted to the shaft 200) is optionally in data communication with the processor 625. A real time clock 630 is optionally in data communication with the processor 625. The processor 625 optionally transmits signals (e.g., at least partially processed signals) from the various sensors to a processor 610 in data communication with the processor 625. The processor 610 is optionally in data communication with a memory 615 (e.g., SD card or other memory). The processor 610 is optionally in fluid communication with a transmitter 605 (e.g., antenna). The transmitter 605 optionally comprises a wireless transmitter (e.g., a WiFi interface access point). The transmitter 605 is optionally at least partially disposed in the cavity 250. The transmitter 605 is optionally in data communication (e.g., wireless communication) with a monitor 690. The monitor 690 optionally comprises a graphical user interface. In some embodiments, the monitor 690 comprises a mobile computing device such as a consumer computing device (e.g., smart phone, tablet, laptop, etc.).

[0023] Referring to FIGS. 7 and 8, another embodiment of a conveyor idler 800 and an associated (e.g., incorporated) idler monitoring system 700 are illustrated. The idler 800 is optionally generally similar to one or more of the other idler embodiments described herein; in some embodiments the idler 800 includes an optionally modified shaft 200 rollingly supporting the cylinder 130. An optionally modified cavity 250 (e.g., in or adjacent to shaft 200) optionally at least partially houses a transmitter 605. The idler 800 optionally includes an identifier 810 (e.g., RFID tag or QR code) which may be provided at or adjacent to the end of shaft 200. A sensor housing 820 (e.g., generally annular housing) is optionally mounted to the shaft 200, e.g., optionally inside the cylinder 130 and optionally between bearings 160.

[0024] As illustrated in FIG. 8, the idler monitoring system 700 optionally includes one or more components described as part of the previously described system 600 (e.g., transmitter 605, clock 630, processor 610, processor 625, memory 615, load sensor amplifier 640, bearing temperature sensors 635). The idler monitor system 700 also optionally includes one or more additional devices in data communication with transmitter 605, e.g., one or more load sensors 720, a vibration sensor, an energy generator 1000, a cylinder temperature sensor 735, an ambient temperature sensor 740, and angle sensor 750. In some embodiments, one or more of the sensors (e.g., sensors 735, 740, and/or 750) are mounted to a circuit board 702 which may also support one or more components described as part of the previously described system 600 (e.g., clock 630, processor 610, processor 625, memory 615, load sensor amplifier 640, etc.). The circuit board 702 is optionally supported on (and/or is optionally at least partially housed in) the housing 820.

[0025] One or more load sensors 720 optionally comprise strain gauges mounted directly to the shaft 200. In some embodiments the load sensors 720 are mounted to a curved (e.g., cylindrical) surface of the shaft; in other embodiments, one or more load sensors are mounted to a machined flat in the shaft and/or a flat surface supported on the shaft. In some embodiments, a first load cell 720a is mounted at a first location on the shaft 200 and a second load cell 720b is mounted at a second location on the opposite side of the shaft. In some embodiments, load cells 720a, 720b are mounted at the same or similar distance from an end of the shaft, such as at or adjacent to the transverse center of the shaft).

[0026] One or more vibration sensors 725 are configured to detect vibration of the idler (e.g., of the bearing 160) and generate a corresponding signal and/or corresponding data to a processor and/or to the transmitter. In some embodiments, the vibration sensor 725 comprises a noise sensor (e.g., an electret microphone). In some embodiments, one or more vibration sensors 725 are in contact with a bearing 160.

[0027] One or more cylinder temperature sensors 735 are optionally configured and positioned to detect the temperature of an inner surface of cylinder 130. In some embodiments, the sensor 735 comprises an infrared temperature sensor optionally oriented toward the inner surface of cylinder 130. In some embodiments, the sensor 735 is at least partially housed in housing 820 and an opening 821 is optionally provided in the housing 820 between the sensor 735 and the inner surface of cylinder 130.

[0028] One or more ambient air temperature sensors 740 (resistance temperature detector, etc.) are optionally configured and positioned to detect the temperature of ambient air inside the idler.

[0029] One or more angle sensors 750 (e.g., accelerometers, etc.) are optionally configured and positioned to generate a signal related to an orientation of the idler (e.g., the idler shaft) relative to horizontal. It should be appreciated that in troughing idler assembly embodiments, the idlers installed in the left, right and center of the assembly may have differing orientations which may be used to identify where the idler is installed on the assembly.

[0030] One or more energy generators 1000 are optionally configured and positioned to generate power by the rotation of cylinder 130 about the shaft 200. Turning to FIG. 10, an embodiment of an energy generator 1000 is illustrated. The energy generator 1000 optionally comprises an inner ring 1040 configured to be supported on (and optionally remain stationary with) shaft 200. The energy generator 1000 optionally comprises an outer ring 1020 configured to be supported in (e.g., press-fit into) and optionally rotate with the cylinder 130. In some embodiments, protuberances 1022, 1042 or roughness elements or other elements are provided on the inner surface of inner ring 1040 and/or on the outer surface of outer ring 1020, respectively. A plurality of radially arranged magnets 1030 (e.g., permanent magnets such as neodymium magnets, etc.) are optionally supported in the outer ring 1020. A plurality of radially arranged electromagnetic coils 1050 (e.g., conductive coils such as copper coils). In operation, rotation of the outer ring 1020 with the cylinder 130 creates energy which is optionally transmitted to an energy storage device (e.g., battery, capacitor) and/or a power-consuming component of the system 700). In some embodiments, energy generation pulses are also transmitted and/or processed by the system 700 to determine a number of rotations and/or a rotational speed of the cylinder 130. In some embodiments, one or more clamps 1010 are positioned to secure the outer ring 1040 to the cylinder 130.

[0031] One or more rotation sensors are optionally provided to detect a rotational speed and/or number of rotations of the cylinder 130. In some embodiments, a signal generated by the energy generator 1000 is used to determine the speed and/or number of rotations of cylinder 130 such that the energy generator 1000 may be considered a rotation sensor. In other embodiments, a different or additional rotation sensor (e.g., Hall effect sensor, etc.) is provided.

[0032] In some embodiments, the rotational speed of the cylinder 130 is compared to a belt speed (e.g., measured or assumed belt speed) in order to estimate a current cylinder diameter and/or current cylinder wear percentage. For example, in some embodiments an adjustment factor based on the comparison between the cylinder rotational speed and belt speed may be applied to a nominal cylinder diameter in order to determine a current cylinder diameter. A percentage wear of the cylinder 130 may be determined by dividing the current cylinder diameter by the nominal cylinder diameter. The calculation steps described herein may be performed by a processor connected to the idler or remote from the idler.

[0033] Referring to FIG. 9, an idler network monitoring system 900 (which may also be referred to as a conveyor monitoring system) is illustrated schematically. In some embodiments, a plurality of systems 700 (e.g., transmitters 605 thereof) are in data communication with communication gateway 950 such as a LoRaWAN gateway, the specifications of which are provided by the LoRa Alliance of Freemont, California. In other embodiments the gateway 950 may be replaced with or supplemented by another communication device such as a WiFi access point. The gateway 950 is optionally in data communication (e.g., via an Internet connection) with an application server 960 (e.g., cloud-based application server). The application server 960 optionally provides data and/or analysis (e.g., failure analysis, diagnostics, etc.) to a web interface 980, a mobile device 990, and/or to a database 970 (e.g., cloud-based database 970).

[0034] In some embodiments, the application server 960 (or other system or device) receives one or more idler-related measurements described herein (e.g., one or more of the measurements carried out by system 700). The application server 960 optionally comprises or makes use of an algorithm (e.g., machine learning algorithm, artificial intelligence algorithm, neural network algorithm, deep learning algorithm, JSON interface, etc.) to predict an idler-related diagnostic (e.g., maintenance interval, failure event, failure event time, first component to fail, etc.) based on the idler-related measurements based on measurements. In some embodiments, the application server identifies an existing idler failure based on one or more idler-related measurements (e.g., temperature, idler rotation speed relative to belt speed or nominal idler rotation speed, shaft load, etc.).

[0035] In some embodiments, a registration device 920 (e.g., including a scanner, camera, etc.) is used to register the idler (e.g., by scanning or taking an image of the identifier 810). In some embodiments, the registration device 920 includes a global positioning (GPS) system or device and optionally identifies the location of each idler upon registration. The registration device is optionally in data communication with the system 900 (e.g., via the gateway, web interface, or other component).

[0036] Referring to FIGS. 11 and 12, in some embodiments a pulley 1100 is optionally provided with one or more load cells 1200 for measuring loads applied to the pulley. In some embodiments the pulley 1100 includes a cylinder 1150 (e.g., metal or other material) having a surface 1125 (e.g., rubber or other material) supported thereon. In some embodiments, the surface 1125 supports one or more radially outwardly extending lagging elements 1122 (e.g., ceramic, rubber or other material). In some embodiments, one or more load cells 1200a are disposed on the cylinder 1150 (e.g., beneath the surface 1125). In some embodiments, one or more load cells 1200b are disposed between the surface 1125 and an optionally modified lagging element 1122. In some embodiments, the pulley 1100 includes a wireless transmitter (not shown) in data communication with a load cell associated with said pulley; in some embodiments the wireless sensor associated with the pulley is in data communication with a gateway or other communication device of a conveyor monitoring system such as the system 900.

[0037] In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output and continuously report sensor output or processed sensor output. In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output but only to report sensor output or processed sensor output at scheduled intervals (e.g., 10 seconds, 30 seconds, 1 minute, 5 minutes, 10 minutes, 30 minutes, 1 hour, 3 hours, 1 day, etc.). In some embodiments, the monitoring systems described herein are configured to continuously monitor sensor output but only to report sensor output or processed sensor output when one or more sensor outputs or processed sensor outputs exceed a threshold (e.g., threshold temperature, threshold vibration level, etc.). In some embodiments, the monitoring systems described herein are configured to only power on and monitor sensor output at scheduled intervals and to report sensor outputs or processed sensor outputs at such intervals or at different intervals.

[0038] Referring to FIG. 13, in some embodiments a user interface (e.g., mobile device 990 or web interface 980, see FIG. 9) is configured to display a summary screen 1300 including various monitoring data generated by system 700. In some embodiments a map 1301 illustrates a location of one or more idlers associated with system 700, which may be superimposed on an aerial image of a conveyor and/or site. An image 1305 of the idler is optionally displayed. A serial number 1302 of the idler is optionally displayed. A battery life indicator 1304 may be displayed. A structural menu 1306 is optionally used to indicate the location of and/or navigate to a given idler on a conveyor (e.g., by selecting a site, conveyor, section of the conveyor, and/or which idler in the idler assembly is of interest). An alarm acknowledgement interface 1310 optionally indicates whether an alarm related to the idler has been acknowledged and/or allows the user to acknowledge the alarm. A real time monitoring display 1320 optionally displays one or more idler measurements (e.g., load, bearing temperature, rotational speed, cylinder ambient temperature, cylinder inner surface temperature, vibration level, etc.). In some embodiments selecting one or more idler measurements in the display 1320 causes the interface to display a graph 1400 of historical values of one or more idler measurements (see FIG. 14). In some embodiments, an alarm history 1330 is displayed indicating which measurements for the idler have set off threshold alarms. In some embodiments, a summary display 1500 (see FIG. 15) may be accessed including summarized measurement displays 1510, 1520, 1530 for a plurality of idlers.

[0039] In some embodiments, the user interface displays a predicted idler-related diagnostic (e.g., maintenance interval, failure event, failure event time, first component to fail, etc.) based on the idler-related measurements. In some embodiments, the user interface displays an indication (e.g., alarm) corresponding to an existing idler failure determined based on one or more idler-related measurements (e.g., temperature, idler rotation speed relative to belt speed or nominal idler rotation speed, shaft load, etc.).

[0040] Ranges recited herein are intended to inclusively recite all values within the range provided in addition to the maximum and minimum range values. Headings used herein are simply for convenience of the reader and are not intended to be understood as limiting or used for any other purpose.

[0041] Although various embodiments have been described above, the details and features of the disclosed embodiments are not intended to be limiting, as many variations and modifications will be readily apparent to those of skill in the art. Accordingly, the scope of the present disclosure is intended to be interpreted broadly and to include all variations and modifications within the scope and spirit of the appended claims and their equivalents.