Patent Description:
The problem is therefore to improve the efficiency of the maintenance of such systems.

The invention is defined by independent claim <NUM>, which solves the disclosed problem, embodiments are presented in the dependent claims. Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, <FIG> and <FIG> illustrate an embodiment of a conveyor idler <NUM>. The conveyor idler <NUM> includes a cylinder <NUM> rollingly supported on a shaft <NUM>. The shaft <NUM> is supported (e.g., in a stationary manner) on a conveyor. The cylinder <NUM> is configured to at least partially support a conveyor belt B.

The idler <NUM> optionally includes end discs <NUM>-<NUM>, <NUM>-<NUM> disposed at opposing ends of the shaft <NUM> and mounted to opposing ends <NUM>-<NUM>, <NUM>-<NUM> of the cylinder <NUM>. Each end disc is optionally supported on an associated bearing <NUM> (e.g., ball bearing). A seal assembly <NUM> 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 <NUM>.

Referring to <FIG>, a monitoring system <NUM> (e.g., one of the monitoring system embodiments described herein) is optionally at least partially supported on the shaft <NUM>.

Referring to <FIG>, one or more mounting boards <NUM>, <NUM> are optionally mounted to the shaft <NUM> for supporting one or more electronic components of the monitoring system <NUM>. In some embodiments, a load sensor <NUM> is supported on (e.g., mounted to the shaft <NUM>). In some embodiments, a cavity <NUM> is provided in an end <NUM> of the shaft <NUM> for housing a transmitter and/or other components of the monitoring system. An opening <NUM> 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 <NUM> and/or other components supported on the shaft <NUM> (e.g., on mounting board <NUM>). In some embodiments, a transmitter is at least partially received in the cavity <NUM>. In alternative embodiments, a cavity <NUM> may be omitted and the transmitter is optionally mounted on the end <NUM> of the shaft or elsewhere on the idler and/or conveyor.

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

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

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

Referring to <FIG> and <FIG>, another embodiment of a conveyor idler <NUM> and an associated (e.g., incorporated) idler monitoring system <NUM> are illustrated. The idler <NUM> is optionally generally similar to one or more of the other idler embodiments described herein; in some embodiments the idler <NUM> includes an optionally modified shaft <NUM>' rollingly supporting the cylinder <NUM>. An optionally modified cavity <NUM>' (e.g., in or adjacent to shaft <NUM>') optionally at least partially houses a transmitter <NUM>. The idler <NUM> optionally includes an identifier <NUM> (e.g., RFID tag or QR code) which may be provided at or adjacent to the end of shaft <NUM>'. A sensor housing <NUM> (e.g., generally annular housing) is optionally mounted to the shaft <NUM>', e.g., optionally inside the cylinder <NUM> and optionally between bearings <NUM>.

As illustrated in <FIG>, the idler monitoring system <NUM> includes one or more transmitters <NUM> and one or more bearing temperature sensors <NUM> and optionally includes one or more components described as part of the previously described system <NUM> (e.g., clock <NUM>, processor <NUM>, processor <NUM>, memory <NUM>, load sensor amplifier <NUM>). The idler monitor system <NUM> includes a vibration sensor and an energy generator <NUM> in data communication with transmitter <NUM> and also optionally includes one or more additional devices in data communication with transmitter <NUM>, e.g., one or more load sensors <NUM>, a cylinder temperature sensor <NUM>, an ambient temperature sensor <NUM>, and angle sensor <NUM>. In some embodiments, one or more of the sensors (e.g., sensors <NUM>, <NUM>, and/or <NUM>) are mounted to a circuit board <NUM> which may also support one or more components described as part of the previously described system <NUM> (e.g., clock <NUM>, processor <NUM>, processor <NUM>, memory <NUM>, load sensor amplifier <NUM>, etc.). The circuit board <NUM> is optionally supported on (and/or is optionally at least partially housed in) the housing <NUM>.

One or more load sensors <NUM> optionally comprise strain gauges mounted directly to the shaft <NUM>'. In some embodiments the load sensors <NUM> 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 <NUM>' 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).

One or more vibration sensors <NUM> are configured to detect vibration of the idler (e.g., of the bearing <NUM>) and generate a corresponding signal and/or corresponding data to a processor and/or to the transmitter. In some embodiments, the vibration sensor <NUM> comprises a noise sensor (e.g., an electret microphone).

One or more cylinder temperature sensors <NUM> are optionally configured and positioned to detect the temperature of an inner surface of cylinder <NUM>. In some embodiments, the sensor <NUM> comprises an infrared temperature sensor optionally oriented toward the inner surface of cylinder <NUM>. In some embodiments, the sensor <NUM> is at least partially housed in housing <NUM> and an opening <NUM> is optionally provided in the housing <NUM> between the sensor <NUM> and the inner surface of cylinder <NUM>.

One or more ambient air temperature sensors <NUM> (resistance temperature detector, etc.) are optionally configured and positioned to detect the temperature of ambient air inside the idler.

One or more angle sensors <NUM> (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.

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

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

In some embodiments, the rotational speed of the cylinder <NUM> 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 <NUM> 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.

Referring to <FIG>, an idler network monitoring system <NUM> (which may also be referred to as a conveyor monitoring system) is illustrated schematically. A plurality of systems <NUM> are, via transmitters <NUM> thereof in data communication with communication gateway <NUM> such as a LoRaWAN gateway, the specifications of which are provided by the LoRa Alliance of Freemont, California. In other examples, not according to the invention, the gateway <NUM> may be replaced with or supplemented by another communication device such as a WiFi access point. The gateway <NUM> is in data communication (e.g., via an Internet connection) with an application server <NUM> (e.g., cloud-based application server). The application server <NUM> optionally provides data and/or analysis (e.g., failure analysis, diagnostics, etc.) to a web interface <NUM>, a mobile device <NUM>, and/or to a database <NUM> (e.g., cloud-based database <NUM>).

The application server <NUM> receives one or more idler-related measurements described herein (i.e. one or more of the measurements carried out by system <NUM>). The application server <NUM> 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.).

In some embodiments, a registration device <NUM> (e.g., including a scanner, camera, etc.) is used to register the idler (e.g., by scanning or taking an image of the identifier <NUM>). In some embodiments, the registration device <NUM> 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 <NUM> (e.g., via the gateway, web interface, or other component).

Referring to <FIG>, in some embodiments a pulley <NUM> is optionally provided with one or more load cells <NUM> for measuring loads applied to the pulley. In some embodiments the pulley <NUM> includes a cylinder <NUM> (e.g., metal or other material) having a surface <NUM> (e.g., rubber or other material) supported thereon. In some embodiments, the surface <NUM> supports one or more radially outwardly extending lagging elements <NUM> (e.g., ceramic, rubber or other material). In some embodiments, one or more load cells 1200a are disposed on the cylinder <NUM> (e.g., beneath the surface <NUM>). In some embodiments, one or more load cells 1200b are disposed between the surface <NUM> and an optionally modified lagging element <NUM>'. In some embodiments, the pulley <NUM> 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 <NUM>.

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.

Claim 1:
A conveyor monitoring system for monitoring a plurality of conveyor idlers (<NUM>) on a conveyor, each conveyor idler having a cylinder (<NUM>) with an inner surface and an outer surface, the cylinder rollingly supported on a shaft (<NUM>) by a plurality of bearings (<NUM>), the conveyor monitoring system comprising:
a plurality of conveyor idler monitoring systems (<NUM>), each comprising:
a bearing temperature sensor (<NUM>) disposed to measure the temperature of at least one of the bearings;
a vibration sensor (<NUM>) configured to detect vibration of the conveyor idler;
a wireless transmitter (<NUM>) in data communication with said bearing temperature sensor and said vibration sensor, said wireless transmitter configured to transmit data from said bearing temperature sensor and said vibration sensor to a wireless receiver; and
an energy generator (<NUM>) in electrical communication with said wireless transmitter, wherein said energy generator is powered by rotation of the cylinder relative to the shaft;
a gateway (<NUM>) in wireless data communication with said wireless transmitter of each conveyor idler monitoring system; characterized in that the conveyor monitoring system comprises
an application server (<NUM>) in data communication with said gateway, said application server is configured to predict an idler failure time for each of the conveyor idlers based on vibration and bearing temperature data gathered by each of said conveyor idler monitoring systems.