RIP DETECTING ANTENNA

Abstract: A conveyor belt having electrically conductive antennas spaced along the direction of movement of the belt and extending from edge to edge of the belt for carrying signals thereacross to detect rips in the belt. The antennas are constructed of a material, the major component thereof being a blend of natural and synthetic rubbers and also including 14% to 18% by weight of electrically conductive carbon black to carry the electrical signals thereacross. In another embodiment, electrically conductive strands, embedded within the electrically conductive material, extend across the belt from edge to edge.

Description: RIP DETECTING ANTENNA BACKGROUND OF THE INVENTION In long endless conveyor belts of the type having an electrically insulating body used to convey bulk material, there is a possibility of encountering a rip in the belt. This may occur, for example by sharp objects being dropped thereon at a loading station. It is desirable to promptly detect such longitudinal rips and, preferably, shut down and repair the conveyor belt upon such detection, thereby minimizing damage to the belt. In prior art structures as described, for example, in U.S. Patent No. 3,792,459 issued to Frank D. Snyder, there is disclosed a conveyor belt rip detecting system of the type in which the instant invention may be employed. In such a rip detection system, a plurality of spaced antennas are imbedded transversly at spaced-apart locations in the belt so as to periodically couple an electrical signal from a transmitter probe to a receiver probe while the belt, with its respective antennas, moves past the electrical sensor probes. The detected electrical signals may thus function to monitor the performance of the belt and shut down the system in response to a break in an antenna which would be indicative of a longitudinal rip in the belt. Detection of the break will permit correction before the break or rip gets too long and destroys an extended portion or even the entirety of the belt or before the belt assembly ceases to function properly. A rip, noted timely, can be corrected with minimum cost and inconvenience. In the prior art devices it has been the general practice to utilize antennas made of metallic screens or wires such as steel extending transversely across the width of the belt, at spaced apart distances. Such wires function properly during normal operations for a period of time. Unfortunately, however, due to movement of the belt and wires around the conveyor rollers of the system, continued flexing stresses upon the wires of the antenna may cause premature breakage of the wires, thus causing a malfunction in the rip detection system. Metallic wires are also susceptible to breakage caused by ore dropped on the belt at a loading station. A broken antenna, caused by failure of any nature, will undesirably give the appearance to the control system that there is a rip in the belt. The system could then improperly shut down the conveying system when in fact there is no such rip in the belt. Alternate progrAmming of the control system may also be employed. Also in the prior art, as described in U.S. Patent No. 4,296,855 issued to Gary L. Blalock, is an alternate form of antenna. Such antenna is constructed of a woven, carbon suffused nylon. Such antennas gerform satisfactorily, with mechanical properties superior to the metallic screen antennas. SUMMARY OF THE INVENTION The present invention relates to an improved electrical conductor particularly useful as an antenna for replacement of the prior art antennas in conveyor belt rip detecting systems. In accordance the the first embodiment of the instant invention, each antenna is constructed principally of natural and synthetic rubber, blended with a significant part of electrically conductive carbon black and with the remaining minority of components being wear resisting agents, antioxidants, vulcanization promoters and other additives to extend the life of the antennas and improve their mechanical, chemical and electrical properties. When vulcanized into a conveyor belt at spaced apart points along the belt length, such rubber members can function as antennas for rip detection Purposes. A rip detecting system provided with a belt having conductive rubber antennas does not suffer from premature breakage of the antennas since conductive rubber antennas can elongate more than prior art antennas without losing their electrically conductive properties. This assures impact resistance of belts in which they are employed. Premature antenna breakage of antennas would cause the loss of electrical conductivity across the belt and between the probes in a control system of the type disclosed in the aforementioned patent to Synder. The new antennas are also cheaper than prior art devices and easier to fabricate into belt systems. Being vulcanized into the belt, they exhibit better mechanical integrity in the belt since they are part of the belt composite, effectively being bonded as one with the belt. In accordance with a second embodiment of the instant invention, each antenna is a composite formed and constructed of a screen or wires encased in a vulcanizable material principally of natural and synthetic rubber, blended with a significant part of electrically conductive carbon black and with the remaining minority of components being wear resisting agents, antioxidants, vulcanization promoters and other additives to extend the life of the antennas and improve their mechanical, chemical and electrical properties. When vulcanized into a conveyor belt at spaced apart points along the belt length, such composite members can function as antennas for rip detection purposes. A rip detecting system provided with a belt having composite antennas does not suffer from premature breakage of the antennas since conductive rubber encasing the wires or screen can elongate more than prior art antennas without breakage or loss of their electrically conductive properties. This assures impact resistance of belts in which they are employed. Further, breakage of a strand of the wires or screen will have negligible effect on the operation of the system due to their encasement in the electrically conductive rubber. Premature antenna breakage of antennas would cause the loss of electrical conductivity across the belt and between the probes in a control system of the type disclosed in the aforementioned patents to Snyder and Blalock. Being vulcanized into the belt, they exhibit better mechanical integrity in the belt since they are part of the belt structure, effectively, being bonded as one with the belt. In order to gain a better understanding of the invention as well as other advantages and further features thereof, reference is made to the following detailed description of the invention to be read in conjunction with the accompanying drawings forming part of this application. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic side elevational view of a conveyor assembly and control system adapted to utilize antennas constructed in accordance with the instant invention; Figure 2 is a schematic sectional view of the assembly of Figure 1 taken through the belt, antenna, sensor probes, and control circuitry; Figure 3 is a perspective view of the belt of Figures 1 and 2 with layers removed to show internal constructions, including the antenna; and Figure 4 is a sectional view of an alternate belt assembly employing the primary embodiment antennas of the instant invention. Figure 5 is a schematic sectional view of the assembly of Figure 1 taken through the belt, antenna, sensor probes, and control circuitry illustrating the record or alternate embodiment of the invention; Figure 6 is a perspective view of the belt of Figure 5 with layers removed to show internal constructions, including the antenna; and Figure 7 is a sectional view of yet an alternate belt assembly employing antennas of the Figures 5 and 6 embodiment of the instant invention. DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in the figures, with particular reference to Figure 1, there is shown a conveyor belt assembly constructed to utilize the antennae made in accordance with the instant invention. The conveyor belt, generally designated as 10. is trained around a plurality of rollers 12 and 14 powered by a drive source, as motor 16. to move the belt in a continuous cycle of operation. The belt has an upper zone or track 18 for conveying ore or other material between a loading station and a discharge station. Opposite the upper zone is a belt return zone 20. The edges of the belt are preferably turned up slightly at their edges at least along the upper surface to minimize spillage of conveyed ore therefrom. The belt is schematically shown as traveling over a short distance between two rollers. It should be understood that belts of this type are readily adapted for conveying ore over great distances including many hundreds or thousands of yards. Further, only two rollers, 12 and 14 are shown for illustrative purposes. Many roller configurations could be suitably utilized to permit conveying of materials great distances, up extended heights and even around corners. Utilized in conjunction with the conveyor belt 10 and drive source 16 is a control mechanism or assembly 22 including electrical sensors or probes 24 and 26 fixedly positioned adjacent the lower surface of the upper track 18 of the belt. Other probe locations to transmit and receive signals may be utilized. The probes are located adjacent opposite edges of the belt and are adapted to monitor its movement and feed electrical signals to the control mechanism 22. This is turn is adapted to act in a servo-loop configuration, thrugh appropriate circuitry. back to motor 16. In this manner, the motive force to the belt may be terminated in response to a rip in any antenna 28 which is fixedly mounted within the belt for movement therewith. In the preferred mode, a plurality of antennas are adapted to be located at fixed, spaced intervals within the belt. These antennae could be spaced at fifty or one hundred feet, or more or less, but generally as a function of the belt size, speed, degree or rip detection protection desired and the control program utilized. The antennas are utilized to detect the presence of broken or unbroken belt segments moving past probes 24 and 26. A more complete understanding of the belt assembly and control system can be had by reference to the aforementioned patent to Snyder. Shown in Figure 3 is the preferred belt construction including an antenna constructed in accordance with the instant invention. The preferred antenna is shown in a conveyor belt wherein it may be beneficially utilized. The belt 10, as shown particularly in Figure 3, may include steel cables 30 which prevent the belt from stretching in the direction of belt movement and which provide great strength to the belt. Reinforcement in both the length and width of the belt is provided by fabric sheets or breakers 32 and 34 on opposite sides of the centrally located cables 30. Various layers of vulcanized elastomeric material such as rubber 36, natural or synthetic combinations thereof blended for belting purposes, are located on opposite sides of the cables 30 and sheets 32 and 34. The cables, sheets and rubber all run in the continuous loop configuration for carrying out the conveying function. An alternate belt construction employing the antenna of the instant invention is shown in Figure 4. The belt 50 has rubber upper and lower cover layers 52 and 54 on opposite faces. Rubberized fabric layers 56 are located between the cover layers with fabric sheets or breakers 58 located at the interfaces between the rubberized fabric layers and cover layers. The breakers are constructed of a fabric material and aid in bonding the carcass layers to the cover layers. They also add impact resistance to the belt. The antennas 28 are located within the cover layer 54. The breakers, covers, and fabric carcass extend continuously along the length of the endless belt. The antennas are spaced along the length of the belt and are adapted to function in the manner of the system described in the aforementioned Snyder patent in carrying electrical changes in the form of signals from the remitter probe 24 to the receiver probe 26 for rip detection purposes. It should be understood, however, that the antennas of the instant invention can function in some embodiments equally well in any belt assembly with or without cables. Breaker plies are preferably utilized in a location between the antennas and steel cables, if steel cables are employed. Located between the layers of rubber are segments of antenna 28 which function for the rip detecting purpose. Each antenna is fabricated of rubber compound mixed using conventional rubber mixing equipment. The rubber preferably contains a majority of natural or synthetic rubber in appropriate blends to constitute a majority of the composition. This majority may constitute from about 50% to 708 by weight of each composite antenna. Preferably, the rubber component should be between 58% and 62% by weight in the preferred embodiment. The second most prevalent component of the composite material of each antenna should be the electrically conductive carbon black. A preferred carbon black is presently marketed by Akzo Chemie Nederland B.V., a Dutch company, and sold under the name of "Ketjen EC". The properties of this material are discussed in the September October 1977 issue of Rubber Chemistry and Technology published by the Rubber Division, American Chemical Society, Inc. Ketjen EC has a lower bulk density, i.e., a lower weight per unit volume, then normal reinforcing carbon blacks commercially available today. It has a specific gravity of about 2.05 plus or minus about 2% as compared to normal carbon blacks which have a specific gravity of from about 1.82 to about 1.86 plus or minus about 2%. This carbon black may constitute from above 10% to under 25% by weight of the composite antennae, preferably from 14% to 18%. The remaining chemicals and additives of the antenna material include antioxidant agents, life extenders, wear resistant materials, vulcanization promoters, processing aids and the like and constitute between 20%-30%, preferably about 24% to.26 by weight, of the antenna material. The constituent components of the antenna material are preferably mixed in a normal fashion and calendered to the appropriate even thickness. They can then be cut to shape to fit across the belt to extend from edge to edge for carrying the electrical signals thereacross. During fabrication, the constituent portions of the belt are laid up or plied together prior to vulcanization. The electrically conductive rubber antennas are then spaced along the length of the belt above the bottom cover layer and the composite belt structure is then vulcanized in the normal fashion. During the vulcanization process of the belt laminate, the elastomeric rubber on opposite sides of each antennae cohere with the rubber of each antennae to hold each antenna in the belt at the proper spacings. The rubber also creates an excellent bond to prevent slippage of the antennae in the belt as during operation. This non-slipping condition is desired since antenna slippage either sideways or along the linear path during operation could cause a malfunction of the detection function. Each antenna is preferably about eight (8) to ten (10) inches in length and extends substantially full width across the belt or at least a distance extending from probe to probe and sufficient to cover the portions of the belt where ripping is likely to occur. Each antenna is normally between 0.030 and 0.060 inches thick and preferably 0.032 inches in thickness and constitutes about 10% of the total belt thickness. The probes are generally about four (4) to six (6) inches in width measured inwardly from the edge of the belt and of a length of about eight (8) to ten (10) inches, substantially equal to that of the antennas. Variations in these dimensions and ratios are acceptable. when employed with covers of about 1/4 inch in thickness or greater, the antennas will fully be incorporated into the belt during vulcanization and the belt will assume an even thickness along its length. If, however, thinner covers are employed, as for example, covers of about 1/16 inch or less, the antennas will be fixedly positioned in the belt but, the belt will have a greater thickness at the antenna locations than at other locations. The rip detecting capabilities of a system employing such belt will not, however, be lost. Further, the greater thickness of the belt at the locations of the antennas will not normally detract from the mechanical operation of such belts. Shown in Figures 5 and 6 is a belt construction including an antenna constructed in accordance with a second or alternate construction made in accordance with the instant invention. The antenna is shown in a conveyor belt-wherein it may be beneficially utilized. Similar parts of the second embodiment utilize the same reference numerals as in the first embodiment. The belt 10, as shown particularly in Figure 6, may include steel cables 30 which prevent the belt from stretching in the direction of belt movement and which provide great strength to the belt. Reinforcement in both the length and width of the belt is provided by fabric sheets or breakers 32 and 34 on opposite sides of the centrally located cables 30. Various layers of vulcanized elastomeric material such as rubber 36, natural or synthetic combinations thereof blended for belting purposes, are located on opposite sides of the cables 30 and sheets 32 and 34. The cables, sheets and rubber all run in the continuous loop configuration for carrying out the conveying function. An alternate belt construction employing the antennae of the embodiment of Figures 5 and 6 is shown in Figure 7. The belt 50 has rubber upper and lower cover layers 52 and 54 on opposite faces. Rubberized fabric layers 56 are located between the cover layers with fabric sheets or breakers 58 located at the interfaces between the rubberized ferric layers and cover layers. The breakers are constructed of a fabric material and aid in bonding the carcass layers to the cover layers. They also add impact resistance to the belt. The antennas 28 are located within the cover layer 54. The breakers, covers, and fabric carcass extend continuously along the length of the endless belt. The antennas are spaced along the length of the belt and are adapted to function in the manner of the system described in the aforementioned Snyder and Blalock patents in carrying electrical changes in the form of signals from the emitter probe 24 to the receiver probe 26 for rip detection purposes. It should be understood, however, that the antennas of the alternate embodiment can function in some embodiments equally well in any belt assembly with or without cables. Breaker plies are preferably utilized in a location between the antennas and steel cables, if steel cables are employed. Located between the layers of rubber are antennas which function for the rip detecting purposes. Each antenna is fabricated of a screen 28 having electrically conductive charge carrying strands or wires extending from edge to edge of the belt. Wires or other strands, electrically insulating or conducting may hold such charge carrying strands in place. These secondary strands are preferably also electrically conductive to increase the charge carrying capability of the screen. The screen is encased in a vulcanizable rubber compound 29 mixed using conventional rubber mixing equipment. The compound preferably contains a majority of natural or synthetic rubber in appropriate blends to constitute a majority of the compound with electrically conductive carbon black as described above in the description of the first embodiment. During the vulcanization process of the belt laminate, which is essentially the same as described above with regard to the first embodiment, the elastomeric rubber compound on opposite sides of each antennae coheres with the rubber of each antennae to hold each antenna in the belt at the proper spacings. The rubber of compound 29 also creates an excellent adhesive and mechanical bond between the antenna interstices to prevent slippage of each antenna in the belt as during operation. This non-slipping condition is desired since antenna slippage either sideways or along the linear path during operation could cause a malfunction of the detection function. While the instant invention is described above with regard to a preferred embodiment, it is intended to be covered broadly within the spirit and scope of the appended claims.

Claims: CLAIMS What is claimed is: Claim 1. A system for detecting a rip in a conveyor belt moveable in a closed path of travel including sensor probe means positioned along the path of travel, and a belt having electrically conductive antennas located within the belt for carrying signals across the belt during normal conditions and for ceasing the carrying of signals when the belt and antenna are ripped, said antennas being constructed of a vulcanizable material principally comprising rubber and also comprising electrically conductive particles of carbon black between more than 10% and less than 25% by weight of the material of the antenna. Claim 2. A system as set forth in claim 1 wherein said antennas being constructed of at least one electrically conductive strand means extending substantially from edge to edge of the belt and said antennas also being constructed of a vulcanizable compound principally comprising rubber and also comprising electrically conductive particles of carbon black between more than 10% and less than 25% by weight of the vulcanizable compound of the antennas encasing said strand means. Claim 3. The system as set forth in claims 1 and 2 wherein said electrically conductive carbon black constitutes between 14% and 18% by weight of the material constituting the antenna. Claim 4. The system as set forth in claims g to 3 wherein the carbon black has a specific gravity of about 2.05 plus or minus 2%. Claim 5. The system as set forth in claim 2 wherein said strand means are part of an electrically conductive screen. Claim 6. The system as set forth in claim 5 wherein said screen is constructed of woven, carbon-suffused nylon. Claim 7. The system as set forth in claim 5 wherein said screen is constructed of steel. Claim 8. A conveyor belt as mentioned in claims 1 to 7 moveable in a closed path of travel, sensor probes positioned along the path of travel, said belt including electrically conductive antennas periodically spaced within the belt for carrying signals across the belt from probe to probe during normal conditions and for ceasing the carrying of signals when the belt and an antenna is ripped, said antennas being constructed of a vulcanizable material principally comprising rubber and also comprising electrically conductive carbon black of a specific gravity of 2.05 plus or minus 28 and constituting between 14% and 18% by weight of the material of the antennas. Claim 9. A conveyor belt as set forth in claim 8 wherein said antennas being constructed of an electrically conductive screen and a vulcanizable compound encasing said screen and extending through the interstices of said screen, said vulcanizable compound principally comprising rubber and also comprising electrically conductive carbon black of a specific gravity of 2.05 plus or minus 2% and constituting between 14% and 185 by weight of the vulcanizable compound of the antennas. Claim 10. For use in a conveyor belt rip detection system, electrically -conductive means extending across the belt substantially from edge to edge and periodically spaced along the direction of movement of the belt, said means including a blend of rubber and electrically conductive carbon black which constitutes in excess of 10% but less than 25% by weight of the blend.

Inventors: HOUCK, ROBERT JAMES, JACOBS, HOWARD LARKIN, KLEIN, RICHARD GRANT
Applicants: THE B.F. GOODRICH COMPANY
Application year: 1982
Main classification: B65G43
IPC codes: B65G43, G01N27