Abstract:
A conveyor belt idler assembly comprises support structure, a strand of catenary idler rollers, and an outboard wing roller or slider bar. The strand of catenary idler rollers can take on various trough-shaped contours. The outboard wing roller or slider bar is attached to the support structure and is able to translate relative to the support structure only along a linear path. The translational movement of the outboard wing roller or slider bar along the linear path is at least partial dependent upon changes in the contour of the strand of catenary idler rollers. The structure is adjustable such that the strand of catenary idler rollers can be lowered and raised to facilitate servicing and installation. A plurality of idler assemblies can be connected to each other using connecting brackets that rigidly tie the assemblies to each other near the outermost idler rollers or slider bars.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       APPENDIX 
       [0003]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention pertains to conveyor belt idler assemblies. More specifically, the present invention pertains to conveyor belt idler assemblies of the type used to support trough-shaped bulk material conveyor belts, especially in loading zones. 
         [0006]    2. General Background 
         [0007]    Bulk material conveyor belts are typically supported by roller and/or slider bar idler assemblies arranged in a trough-shaped manner. In material loading zones, multiple idler assemblies are often arranged in series and in close proximity to each other to form impact cradles or beds that are capable of supporting the impact loads generated by material being loaded onto the belts. Ideally, the trough-shape formed by the idler assemblies should match the theoretical contour that the belt would naturally have given the load distribution on the belt (which, in general, is greatest at the center of the belt and follows a bell-shaped curve transversely across the belt). In actuality however, since the loading conditions on a given belt conveyor change during use, so too does the theoretical ideal profile of the belt. For this and other reasons, some idler assemblies (especially in high-load and/or high-speed applications) utilize what are often referred to as catenary idlers. A catenary idler assembly comprises a strand of several idler rollers and/or slider bars that are flexibly linked to each other. The strands are suspended such that the trough-shape formed by the idler assemblies can adjust in a catenary-like manner as the load distributions on the belt change. 
         [0008]    Another driving force behind the design of impact-zone idler assemblies is the need to provide effective sealing. In belt loading zones, dust suppression and spillage are almost always a concern. To address this, conveyor belt systems typically are provided with generally fixed seals that slideably contact the upper surface of the belts near their outboard edges in loading zones. As can be appreciated, better sealing can be achieved by controlling the angular orientation of the outboard edge portions of the belt in the loading zone such that the angular orientations match the angular orientations of the sliding seals. Additionally, it is desirable to minimize belt sag between idler assemblies so that the edge margins of the belt are as linear as possible as the belt passes through the loading zone. These design goals conflict with the design goals of catenary idler assemblies since the goal of catenary idler assemblies is to allow the belt contour to adjust with changes in load distributions. Moreover, catenary idler assemblies generally are spaced farther apart from each other as compared to fixed idler assemblies to accommodate slight swinging of the suspended rollers. Spacing the idler assemblies farther apart can increase the degree of belt sag between the idler assemblies, which decreases belt sealing performance. 
         [0009]    To address the conflict between the above-mentioned design goals, idler assemblies have been provided with fixed outboard or wing idler rollers or sliding bars, and with a catenary strand of idler rollers therebetween. In some cases, in addition to the normal flexibility of the catenary string, the catenary string is suspended from spring-biased mounting points to further improve the ability of the rollers to adapt to various contours and to reduce peak impact loads. However, utilizing such spring-biased catenary rollers in combination with fixed wing rollers or slider bars creates another problem. More specifically, as a spring-biased catenary strand of rollers changes the contour of the center of the belt, the outboard edges of the belt must move relative to each other. This means that there is transverse movement of the belt edge margins over the fixed wing idlers, which increases friction and belt wear. 
         [0010]    Another problem associated with catenary idler assemblies is that catenary strands of idler rollers are inherently difficult to install or replace due to their flexibility and limp nature and due to the fact that the entire weight of a strand must be counteracted when installing the strand. These difficulties also increase the likelihood of injury to those providing installation or repair services. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention overcomes some of the problems associated with catenary type idler assemblies. The idler assemblies of the present invention are capable of handling conveyor belts having high loads and high speeds without sacrificing sealing performance or increasing friction. Moreover, the idler assemblies of the present invention are adjustable in a manner simplifying the installation and servicing of such assemblies. 
         [0012]    In one aspect of the invention, a conveyor belt idler assembly comprises support structure, a strand of catenary idler rollers, and an outboard wing roller or slider bar. The strand of catenary idler rollers can take on various trough-shaped contours. The outboard wing roller or slider bar is attached to the support structure and is able to translate relative to the support structure only along a linear path. The translational movement of the outboard wing roller or slider bar along the linear path is at least partially dependent upon changes in the contour of the strand of catenary idler rollers. 
         [0013]    In another aspect of the invention, a conveyor belt idler assembly comprises support structure, at least three suspended conveyor belt idler rollers, first and second connecting members, and first and second belt support members. The conveyor belt idler rollers are flexibly linked to each other in a chain-like manner and are flexibly linked to the first and second connecting members in a manner such that the conveyor belt idler rollers are suspended from and between the first and second connecting members and hang in a catenary manner from the first and second connecting members. Each of the first and second connecting members are movably attached to the support member in a manner such that said connecting member cannot pivot relative to the support member but can translate along a linear path relative to the support member. The first belt support member is supported by and movable with the first connecting member relative to the support structure. The second belt support member is supported by and movable with the second connecting member relative to the support structure. The first and second belt support members and the conveyor belt rollers collectively form a trough-shape and each is configured and adapted to engage and support a conveyor belt positioned in and moving through the trough-shape. 
         [0014]    In yet another aspect of the invention, a conveyor belt idler assembly comprises a strand of catenary idler rollers and support structure. The strand of idler rollers is attached to the support structure. The support structure is adjustable between an operation configuration and a servicing configuration. The strand of idler rollers is suspended from the support structure when the support structure is in the operation configuration, but rests on the support structure when the support structure is in the servicing configuration. 
         [0015]    In still another aspect of the invention, an impact cradle comprises at least two conveyor belt idler assemblies arranged in series and in close proximity. Each idler assembly comprises support structure and a plurality of idler rollers and/or slider bars arranged in a trough-shape. The idler rollers and/or slider bars include opposite outermost idler rollers or slider bars. The connecting brackets rigidly tie adjacent portions of the support structures of adjacent conveyor belt assemblies to each other. The adjacent portions are proximate to the outermost idler rollers or slider bars. 
         [0016]    Further features and advantages of the present invention, as well as the operation of the invention, are described in detail below with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  depicts a perspective view of an embodiment of an idler assembly in accordance with the present invention, and shows the idler assembly in its operation condition. 
           [0018]      FIG. 2  depicts a perspective view of the idler assembly shown in  FIG. 1 , and shows the idler assembly between its operation condition and servicing condition. 
           [0019]      FIG. 3  depicts a perspective view of the idler assembly shown in  FIGS. 1 and 2 , and shows the idler assembly in its servicing condition. 
           [0020]      FIG. 4  depicts a detail view of the idler assembly shown in  FIGS. 1-3 , showing the underside of the distal portion of one of its support arms. 
           [0021]      FIG. 5  depicts a detail elevation view of the idler assembly shown in  FIGS. 1-3 , showing a close-up of one of its adjustable braces. 
           [0022]      FIG. 6  depicts a perspective view of an assembly of four idler assemblies of the type shown in  FIGS. 1-3 . 
       
    
    
       [0023]    Reference numerals in the written specification and in the drawing figures indicate corresponding items. 
       DETAILED DESCRIPTION 
       [0024]    A preferred embodiment of an idler assembly in accordance with the present invention is shown in the figures and is indicated by the numeral  10 . The idler assembly  10  comprises support structure  12 , wing rollers  14 , and a strand of rollers  16 . 
         [0025]    The support structure  12  comprises a base  18 , a pair of support arms  20 , a pair of adjustable braces  22 , a pair of spring biased movable carriages  24 , and a hydraulic actuator  26 . The support structure  12  (excluding the hydraulic actuator  26 ) is formed primarily of laser cut pieces of steel that are interlocked with each other and that are thereafter welded together. Each of the support arms  20  comprises a proximal portion  28  that is pivotally attached to the base  18  near the center of the base. In normal operation, the support arms  20  extend upward and outward from the base  18  and are held in that upright configuration by the adjustable braces  22 . Each of the adjustable braces  22  is attached to the base  18  and to the distal portion  30  of a respective one of the support arms  20 . Each carriage  24  is slideably attached to the distal portion  30  of a respective one of the support arms  20  in a manner such that the carriage is able to translate along an axis relative to the distal portion, but is otherwise constrained by the support arm. Those axes are defined by railing components  32  that secure the carriages  24  to the support arms  20 . The distal portion  30  of each support arm  30  also comprises a threaded rod  34 , a compression spring  36 , and an adjustable spring stop  38  (see  FIG. 4 ). The threaded rod  34  acts as an adjustment screw that repositions the spring stop  38  along the axis of the rod. The compression spring  36  is sandwiched between the spring stop  38  and the carriage  24  in a manner such that movement of the carriage  24  toward the center of the idler assembly  10  relative to the distal portion  30  of the respective support arm  20  is resisted by the spring. Preferably, each compression spring  36  has a stiffness of 2200 lbs/inch and allows for a maximum compression of only one inch. Thus, in normal operation (as is further described below), the carriage  24  is able to move linearly relative to the support arm  20 , but only by a relatively small amount. 
         [0026]    The support structure  12  supports the wing rollers  14  and the strand of rollers  16  as shown in  FIG. 1 . Preferably, each carriage  24  has two wing rollers  14  attached to it in a manner such that the wing rollers  14  are movable with the carriage relative to the respective support arm  20 . The two wing rollers  14  are positioned side-by-side in a non-collinear manner and are able to rotate about axes that are preferably oriented parallel to the linear moveability of the carriage  24  relative to the respective support arm  20 . The strand of rollers  16  is suspended from and between the carriages  18  in a manner such that the strand of rollers hangs from the carriages in a catenary-like manner. The individual rollers of the strand of rollers  16  are preferably connected to each other via chain links in a manner to provide one degree of rotational freedom between them. Each of the opposites ends of the strand of rollers  16  are preferably connected to the respective carriage  24  via two chain links that provide two degrees of rotational freedom and that functions like a universal joint. Preferably the strand of rollers  16  is centered along the direction of belt travel between the two wing rollers  14  of each carriage  24 . 
         [0027]    In normal operation, an endless conveyor belt  40  (shown in  FIG. 1  represented by only a small portion of the belt) rides in the trough formed by the wing rollers  14  and the strand of rollers  16 . As vertical loads on the conveyor belt  40  vary, the compression springs  36  compress and decompress in a manner moving the carriages  24  slightly such that the peak load experienced by the strand of rollers  16  is far less than it would be if the strand of rollers was suspending from fixed points. This of course moves the belt  40  up and down slightly along its centerline. Because the wing rollers  14  move with the carriages  24 , the belt  40  does not need to slip over the wing rollers (i.e., slide over the rollers in direction parallel to the rotational axes of the rollers). This reduces friction as compared to if the wing rollers  14  were fixed in place. Still further, because the wing rollers  14  are each only capable of translating along a linear path with the respective carriage  24 , the angles of orientation of the wing rollers  14  (in the plane that is perpendicular to the direction of belt travel) remain constant. That in turn ensures that the end margins of the belt  40  will maintain the proper angular and vertical orientations to effectuate proper belt sealing despite the fact that the belt contour is able to adjust. 
         [0028]    When servicing or installing the idler assembly  10 , the support arms  20  of the support structure  12  can be lowered, which greatly facilitates such servicing or installation. To lower the support arms  20 , the support arms are initially raised slightly so that the adjustable braces  22  that normally hold up the support arms can be released. The adjustable braces  22  operate as over-center locking mechanisms. Each of the adjustable braces  22  (shown in isolation in  FIG. 5 ) preferably comprises an upper member  42 , a lower member  44 , and an adjustable cam  46 . The upper and lower members  42 ,  44  are pivotally connected to each other. The upper member  42  is pivotally connected to the respective support arm  20 , and the lower member  44  is pivotally connected to the base  18  of the support structure  12 . The adjustable cam  46  limits the degree to which the upper and lower members  42 ,  44  can pivot relative to each other. Thus, when the hinge axis about which the upper and lower members  42 ,  44  connected to each other lies outboard (as shown in  FIG. 1  and as it does in normal operation), the cam  46  prevents the adjustable brace  22  from collapsing and the bracket  22  can therefore support the vertical load acting on the support arm  20 . But when the support arm  20  is raised slightly, the hinge axis can be forced inboard, which allows the bracket  22  to ultimately collapse, as is shown in  FIGS. 2 and 3 . It should also be appreciated that the cam  46  is adjustable in a manner such that the maximum outboard angle between the upper and lower members  42 ,  44  can be adjusted to finely control how high the support arm  20  is held during normal operation. This simplifies the process of properly aligning the idler assembly  10  with other components of a belt conveyor system. 
         [0029]    To facilitate the raising and lowering of the support arms  20 , a technician preferably operates the hydraulic actuator  26  of the support structure  12 . To pressurize the hydraulic actuator  26 , a technician preferably attaches a manual or battery operated hydraulic pump to a quick disconnect fitting  48  that is provided on the support structure  12 . Before lowering the support arms  20  however, a technician preferably also actuates the threaded rods  34  on the distal portion  30  of each support arm  20  to move the spring stops  38 , and therefore also the carriages  24 , inboard. This provides additional slack in the catenary strand of rollers  16  to ensure that the strand of rollers  16  won&#39;t be drawn taut as the support arms  20  are lowered. With the support arms  20  lowered, technicians are able to install or replace the rollers of the idler assembly  10 . Moreover, as shown in  FIG. 3 , when the support arms  20  are lowered, the strand of rollers  16  can rest partially on the base  18  of the support structure  20 . This makes it much easier to replace the rollers of the strand of rollers  16  or to install a new strand of rollers since the strand needs not be serviced or installed while it is suspended. 
         [0030]    As shown in  FIG. 6 , a plurality of the idler assemblies  10  can be arranged in series to form an impact cradle  50 . As mentioned above, like in prior art catenary impact cradles, the impact assemblies  10  are configured such that the strands of rollers  16  are spaced apart by a sufficient distance to allow the strands of rollers  16  to swing slightly. Notably however, by providing two wing rollers  14  on each support arm  20  of each idler assembly  10 , the wing rollers are tightly spaced. This greatly reduces belt sag between the wing rollers  14  and thereby improves belt sealing. Additionally, to further improve belt sealing, the idler assemblies are preferably interlocked together via brackets  52  that lock the distal portions  30  of the support arms  20  together along each side of the impact cradle  50 . By interlocking the support arms  20  in this manner, the support arms  20  deflect less, both vertically and in the direction of belt travel, and this further improves belt sealing. 
         [0031]    In view of the foregoing, it should be appreciated that the invention has several advantages over the prior art. 
         [0032]    As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, it should be appreciated that low friction slider bars could be used in place of the wing rollers, which would eliminate belt sag in sealing areas at the costs of greater friction. Additionally, as another example, other structure could be used in place of the carriages to achieve the linear moveability of the wing rollers or slider bars. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 
         [0033]    It should also be understood that when introducing elements of the present invention in the claims or in the above description of exemplary embodiments of the invention, the terms “comprising,” “including,” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements. Additionally, the term “portion” should be construed as meaning some or all of the item or element that it qualifies. Moreover, use of identifiers such as first, second, and third should not be construed in a manner imposing any relative position or time sequence between limitations. Still further, the order in which the steps of any method claim that follows are presented should not be construed in a manner limiting the order in which such steps must be performed, unless such an order is inherent.