AU2016245324B2

AU2016245324B2 - Conveyor pulley monitoring apparatus

Info

Publication number: AU2016245324B2
Application number: AU2016245324A
Authority: AU
Inventors: Nicholas Coplin; Wasyl DZIOMBAK; Mehrdad JAVADI; Antonio LUTZU; Donald Mark Okeby; Vincent POTTIER; Tyron Utley
Original assignee: Orontide Group Ltd
Current assignee: Orontide Group Ltd
Priority date: 2015-04-10
Filing date: 2016-04-08
Publication date: 2020-01-02
Anticipated expiration: 2036-04-08
Also published as: AU2016245324A1; WO2016161473A1

Abstract

A monitoring apparatus for a conveyor pulley, wherein the conveyor pulley is fastened to a pulley shaft using a locking device. The monitoring apparatus comprises sensing means capable of detecting and measuring one or more physical phenomena, activities or conditions associated with the conveyor pulley. The sensing means are integrated into a protective cover of the locking device.

Description

TITLE “CONVEYOR PULLEY MON If ORING APPARATUS”

FIELD OF INVENTION [0001] The present invention relates to a conveyer pulley monitoring apparatus. In particular, the invention relates to a conveyor pulley monitoring apparatus integrated into a conveyor pulley locking device cover.

BACKGROUND [0002] Conveyor systems are used in manufacturing and industry in a variety of situations where objects and materials need to be transported between locations. A conveyor system typically comprises a set of conveyor pulleys and rollers arranged in succession along the intended conveyor path. A conveyor belt runs around the sei of conveyor pulleys and, in use, is moved by one or more conveyor pulleys that are powered {drive conveyor pulleys).

[0(103] Each conveyor pulley comprises a pulley drum or shell with a pair of opposed end plates. During assembly of the conveyor pulley, a pulley shaft is installed through a central bore in each of the end plates and through the pulley shed. Once the shaft has been centralized and positioned correcily, an expandable locking device is used to fasten the pulley shell anti its end plates to the shaft in the optimal position.

[0004] A common locking device that is used comprises a disc-shaped collar that engages around the pulley shaft and occupies the space formed between the shaft and the pulley end plate bores. The collar has a set of tensioned bolts (being a bolt tightened to a specific torque) arranged about, the collar’s outer circumference. Each bolt passes through the collar.

[0005] Tightening the tensioned bolts causes the collar's outer perimeter surface to expand, thereby increasing the collar’s circumferenee, and causes the coftar’s inner

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PCT/AU2016/000121 perimeter surface to constrict.. This clamps the pulley end plates to the pulley shaft by a strong interference fit and fastens the pulley shell to the shaft.

(0006] After a pulley shell has been fastened to its shaft, an additional protective cover may be fitted over the external parts of the locking device that remain exposed. The protective cover is typically .manufactured from a high-grade steel material, or tough non-metallic material, and serves to shield the locking device and its tensioned bolts from the external environment. The cover protects the locking device from damage including corrosion and any impacts that may take place during use or transportation of the conveyor pulley.

[1)1107] These conveyor systems can suffer significant wear and tear during use and it is not uncommon for parts to degrade or fail. In particular, it i s known for the tensioned bolts of a locking device to crack or break as a result of corrosion or locking device fatigue caused by, for example, heavy or irregular conveyor loads. Damaged tensioned bolts significantly reduce the strength of a locking device and, by extension, the pulleyshcl 1-to -shaft fastening.

[0008] It is, therefore, vital that tensioned damaged bolts are identified and replaced by conveyor maintenance personnel as soon as possible. If the conveyor pulley assembly also has a protective cover installed over its locking device, it is not uncommon for tensioned bolt failures to go unnoticed for a substantial period of time, which can lead to catastrophic failure or serious damage to the conveyor pulley assembly.

[()009] Significant vibrational forces also act on conveyor systems during use, particularly in heavy industry and mining. Excessive vibrations can cause damage to conveyor system parts and unusual vibrations may be symptomatic of component failures that have occurred, including components not immediately visible to, or accessible by. maintenance personnel.

[0010] Other types of physical phenomena can also be experienced by and/or act on conveyor systems during their use causing, or being symptomatic of -component or system failure or misuse including, for example, excessive loads, noise, temperature and conveyor pulley rotational speed.

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PCT/AU2016/000121 [OOH] The present invention attempts to overcome, at least: in part, the aforementioned problems associated with conveyor systems.

SUMMARY OF T HE INVENTION [0012] In accordance with one aspect of the present invention, there is provided a conveyor pulley monitoring apparatus, the monitoring apparatus comprising sensing means, wherein the sensing means are integral with a conveyor pulley locking device protective cos er.

10013] The protective cover preferably comprises an exterior surface and interior surface, wherein the. exterior surface preferably has a substantially convex shape and the interior surface preferably has a substantially concave shape and defines an interior area of the protective cover. Preferably, a hole passes through a centre of the protective cover though, which a conveyor pulley shaft may be received and pass. In a preferred embodiment, the protective cover is substantially disc shaped. In a further preferred embodiment, the protective cover comprises a first half and a second half, wherein the second half is substantially symmetrical to the first half. The protective cover is made from a resilient non-mclaJlic material and, preferably, a carbon or a composite carbon and Kevlar* based filament material.

[0014] The integrated sensing means preferably comprises one or more sensing devices, wherein each sensing device is capable of detecting and measuring one or more physical phenomena, activities or conditions associated with a conveyor pulley. The. or each, sensing device is preferably disposed in the interior area of the protective cover. Alternatively, the. or each, sensing device is embedded between the interior surface and the exterior surface of the protective cover.

[0015] The, or each, sensing device preferably comprises an. anti-tamper device that is capable of indicating when the, or each, sensing device has been serviced by unauthorized personnel. Preferably the, or each, anti-tamper device comprises a volume of non-conductive liquid adhesive. Alternatively, the, or each, anti-tamper device comprises a piece of foil tape.

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PCT/AU2016/000121 [0016’J The protective cover preferably also comprises a wireless data transmission system for wirelessly transmitting information collected using the, or each, sensing device to a peripheral device, such as a handheld device operated by a serviceperson. Preferably, the transmission system uses Bluetooth', a wireless local area network (WiFi) or other appropriate wireless communications technology.

[()()17] In a preferred embodiment, at least one sensing device comprises a tensioned bolt sensor preferably disposed substantially opposite to a tensioned bolt of a locking device installed on the conveyor pulley and is capable of detecting a break, crack or other adverse issue associated with the tensioned bolt. Preferably, the tensioned boll sensor is affixed to the interior surface of the protective cox er and comprises an electronic trigger that engages when a part of the tensioned boh breaks and/or comes loose. Preferably, the electronic trigger engages when the part comes into contact with the electronic trigger or the electronic trigger detects a difference in the distance between the bolt and the electronic trigger.

[0018] In a further preferred embodiment, at least one sensing device comprises a vibration sensor capable of detecting and measuring one or more vibrational forces acting on and/or experienced by the conveyor pulley and/or a conveyor system in which the conveyor pulley is installed.

[0019] In a further preferred embodiment, at least one sensing device comprises a tachometer capable of measuring a rotational speed of the conveyor pulley in revolutions per minute (RP.M).

[0020] In a farther preferred embodiment, at least one sensing device comprises a pulley shaft deformation sensor capable of detecting and measuring one or more deformations and/or deflections to a pulley shaft that passes through the conveyor pulley. Preferably, the pulley shaft deformation sensor operates in conjunction with one or more strain gauges affixed to the pulley shaft.

[00211 In a further preferred embodiment, at least one sensing device comprises a pulley shell end plate deformation sensor capable of detecting and measuring one or

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PCT/AU2016/000121 more deformations to a pulley shell end plate. Preferably, the pulley shell end plate deformation sensor operates in conjunction with one or more strain gauges affixed tc> the end plate.

[0()22] In a further preferred embodiment, at least one sensing device comprises a sensor capable of measuring a temperature of the conveyor pulley or a part of the conveyor system in which the conveyor pulley is installed.

[0023] In a further preferred embodiment, at least one sensing device comprises a sensor capable of detecting and measuring excessive lubricant present in a region of the conveyor pulley or a part of the conveyor system in which the conveyor pulley is installed.

[0024] In a further preferred embodiment, at least one sensing dex ice comprises a particle sensor capable of detecting and measuring particle contamination in a lubrication system of the conveyor pulley. Preferably, the particle sensor is capable of detecting and measuring particle contamination that comprises metal filings originating from one or more bearings, bearing housings and/or bearing accessories attached or near to a bearing housing of the conveyor pulley. Preferably, the particle sensor is capable of detecting and measuring particle contamination that comprises metal filings originating from one or more grease labyrinths of the conveyor pulley.

[0025] In a further preferred embodiment, the protective cover further comprises an identification means integrated with the protective cover. The identification means preferably comprises a radio-lrequency identification (RFID) tag connected to the protective cover, wherein the RFID tag lias a unique identification (or “serial”) number electronically encoded in the RFID tag that identifies the protective cover and the conveyor pulley. Preferably, the RFID tag is embedded between the interior surface and the exterior surface of the protective cover and can be read whilst the conveyor pulley is still running.

[()026] In a further preferred embodiment of the present invention, the protective cover preferably comprises an outer cover, an inner cover and a sensor board.

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PCT/AU2016/000121 [0027] The sensor board may be disposed inside a first cavity of the protective cover, wherein the first cavity is formed between the outer cover and inner cover.

[0028] The protective cover may fort it er comprise a bolt guide layer that defines a second cavity of the protective cover, wherein the second cavity is adapted to enclose, at least in part, one or more tensioned bolls of die locking device.

[0029] The second cavity may have a pair of opposed walls that are substantially tapered, wherein the opposed walls arc adapted to guide a tensioned bolt (or part thereof) that breaks atid/or comes loose towards the sensor board during operation of the conveyor pulley.

[0030] The sensor board may comprise a plurality of sectors arranged about a common centre to form a substantially circular shape, wherein each sector comprises a sensing region and a control region.

[0031] Each sensing region of each sector may comprise one or more inductive metal sensors.

10032] Alternatively, each sensing region of each sector may comprise one or more ultrasonic, optical, capacitive. magnetic, 11 all-effect or other proximity or distance-based sensors.

[0033] Each control region of each sector may be adapted to communicate with one or more other control regions of others sectors of the sensor board and/or with a peripheral device.

[0034] In accordance with a further embodiment of the present invention, there is provided a method for monitoring a conveyor pulley, the method comprising the steps of:

integrating sensing means into a locking device protective cover; installing the protective cover to a locking device of the conveyor pulley; and

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PCT/AU2016/000121 using the sensing means io monitor the conveyor pulley when the conveyor pulley is in operation.

BRIEF DESCRIPTION OF DRAWHSGS [0035] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[()1)36] Future 1(a) shows an isometric view of a conveyor pulley locking device as known in the art;

[0037] Figure 1 tb) shows a partial side view of the locking device of Figure 1(a):

[0038] Figure 2 shows a partial isometric view of a conveyor pulley fastened to a pulley shaft using the locking device of Figure 1(a ), as known in the art:

[0039] Figure 3 shows a further partial isometric view of the arrangement shown in Figure 2, wherein the locking device has installed thereon a conveyor pulley monitoring apparatus according to a first embodiment of the present invention;

[0040] Figure 4 shows a partial side view of the arrangement shown in Figure 3;

[0041] Figure 5 shows a partial schematic side view of a conveyor pulley and shaft arrangement that, has installed thereon a com cyor pulley monitoring apparatus according to a second embodiment of the present invention;

[0042] Figure 6 shows a partial enlarged schematic view of the monitoring apparatus shown in Figure 5;

[00431 Figure 7 shows a schematic representation of a sensor board that may be used with the second embodiment shown in Figure 5;

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PCT/AU2016/000121 [0044] Figure 8 shows a schematic diagram of electronic components comprised in an electronic architecture utilised in the second, embodiment shown in Figure 5;

[0045] Figure 9(a) shows a schematic diagram of electronic comjxmcnis comprised in an inducti ve metal sensor used in the second embodiment shown in Figure 5;

[0046] Figure 9(b) shows a schematic diagram of a plurality of inductive metal sensors arranged in a daisy-chain configuration; and [0047] Figure 10 is a schematie flow diagram showing, execution steps of management software embedded in a microcomroller used in. the second embodiment shown in Figure 5<

DETAILED DESCRIPTION OF THE DRAWINGS [0048] Referring to f igure 1(a), there is shown an example of a conveyor pulley locking device 1 known in the art. The locking device 1 comprises a disc-shaped collar 3 that has a plurality of tensioned bolts 5 disposed about an outer circum ference 4 of the collar 3. Each tensioned bolt 5 passes through the collar 3 transversely.

[0049] As shown in Figure 1(b), each tensioned bolt 5 comprises a bolt head 7 and a bolt shank 9. The collar 3 further comprises a pair of inner wedge members 11, a lower outer wedge member 13 and an upper outer wedge member 15.

[0050] In use, when the bolt head 7 is tightened the tensioned bolt 5 is drawn into the collar 3 causing the inner wedge members 11 to be urged into the region between the lower outer wedge member 13 and the upper outer wedge member 15. This, in turn, forces the upper outer wedge member 15 in the direction indicated by reference numeral 17 and forces the lower outer wedge member 13 in the direction indicated by reference numeral 19. This causes the outer circumference of the collar 3 to expand forcefully and causes the circumference of the collar’s 3 inner surface 20 lo constrict.

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PCT/AU2016/000121 [005 I I Referring to Figure 2. there is shown a conveyor pulley 21 fastened to a pulley shaft 23 using the locking device I. as is known, in the art. The conveyor pulley 21 comprises a hollow cylindrical pulley shell 25 with a circular end plate 27 disposed at a first end of the conveyor pulley 2.1. A second circular end plate is disposed at a second end of the conveyor pulley 21 (not shown).

[0052] The: end plate 27 has a bore 29 at its centre. During assembly of the pulley 21, the pulley shaft 23 is received into and ted through the bore 29 and through the hollow interior of the pulley shell 25.

[0053 j .After the shaft 2.3 has been moved into its correct central position, the locking device 1 is then assembled onto the pulley shaft 23 so that it occupies the space that is formed around the pulley shaft 23 between the pulley shaft 23 and the inside surface (not shown) of the bore 29 of the circular end plate 27. Each of the tensioned bolts 5 are then tightened which causes the outer circumference of the collar 3 to expand and, in turn, causes the circumference of the inner surface 20 of the collar 3 to constrict. I his firmly locks the pulley shell 25 to the pulley shaft 23..

[0054] Referring to Figures 3 and 4, there is shown a conveyor pulley monitoring apparatus 31 according to a first embodiment of the present invention. The monitoring apparatus 31 is installed to a conventional conveyor pulley 30 that has been fastened to a pulley shaft 42 using a locking device 1.

[0055] The monitoring apparatus 31 comprises a conveyor pulley locking device protective cover 32. As most dearly shown in Figure 4, the protective cover 32 preferably comprises an interior surface 34 and an exterior surface 36. The exterior surface 36 is substantially convex in shape and the interior surface 34 is substantially concave in shape and defines an interior area 38 of the protective cover 32.

[0056] A hole 40: passes through a centre area of the protective cover 32 which permits the protective cover 32 to be received and fitted onto the pulley shaft. 42 during installation and pushed down until it substantially encloses the locking device 1. Once

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PCT/AU2016/000121 the protective cover 32 is in its correct position, it is fastened to an end plate 50 of the conveyor pulley 30 by, for example. bolting the protective cover .32 to the end plate 50.

[0057] As best shown in Figure \ the protective cover 32 is substantially disc shaped. It Will be appreciated, however, that alternative shapes arc possible, for example, square, rectangular or polygon shapes, which are also within the scope of the present invention.

[0058] Further, in alternative embodiments of the present invention, the protective cover 32 may have a specific colour that indicates the type of the conveyor pulley monitoring apparatus 31 and/or indicates that, the conveyor pulley monitoring apparatus 31 has received certain upgrades during its service history.

[00591 In a further preferred embodiment, the protective cover 32 may comprise a first half (not shown) and a second half (not shown) wherein the second half is substantially symmetrical and complementary’ to the fjr*t half. Having the protective cover 32 consisting of two complementary halves allows the protective cover 32 to he partially dismantled and serviced, which may include retrofitting new parts, without completely removing the protective cover 32 from the conveyor pulley 30 that it is installed to.

[0060] According io the present invention, the protective cover 32 comprises integrated sensing means. It is an objective of the present invention to provide a practical and effective device for detecting and measuring various physical phenomena, conditions or activities that may indicate actual, pending or potential structural or operational failures or degradation of a conveyor pulley, or conveyor system in which a conveyor pulley is installed.

[0061] It will be appreciated that the protective cover 32 of the present invention is situated in close proximity to the locking device I, which is a common point of failure for conveyor pulleys. As best shown in Figure 3. the protective cover 32 will also commonly be situated in close proximity to a bearing housing 48 that receives the pulley shaft 42, which is also a common point of failure. The protective cover 32 is. therefore, an ideal apparatus for housing sensing means.

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PCT/AU2016/000121 [0062] Accordingly, the sensing means in the present invention preferably comprises one or more sensing devices integrated into the protective cover 32. Each sensing device is capable of detecting and measuring one or more physical phenomena, conditions or activities associated with the conveyor pulley 30 and is preferably disposed m the interior area 38 of the protective cover 32, [()063] The components comprising the, or each, sensing device arc robust and capable of withstanding substantial vibrations, shock and other physical conditions that they may be subjected to during use.

10064j 'fbe, or each, sensing device may also comprise an anti-tamper device that is capable of incapacitating the sensing device or indicating when unauthorized personnel attempt to open or access the components comprising the sensing device. For example, each anti-tamper device may comprise a volume of non-conductivc liquid adhesive that adheres one or more vital components of the sensing device to a wall of the sensing device's housing. Attempting to open the housing causes the adhesive to damage the vital components permanently. Alternatively, the anti-tamper device may comprise a length of foil tape. The foil tape is arranged such that the tape will be toni when a person attempts to open or access the components comprising the sensing device.

[()065 j The protective cover 32 preferably also comprises a wireless data transmission system (now shown) for wirelessly transmitting information collected using the, or each, sensing device to a peripheral device such as a handheld device operated by a serviceperson. Preferably, the transmission system uses Bluetooth \ a wireless local area network (Wi-Fi) or other appropriate wireless communications technology.

[0066Ί In the exemplary·' embodiment shown in Figures 3 and 4, a plurality of sensing devices is shown wherein each sensing device comprises a tensioned bolt sensor 44.

[0067] Each tensioned bolt sensor 44 is preferably disposed in the interior area 38 of the protective cover 32 substantially opposite a tensioned bolt 5 of the locking device 1 and is capable of detecting a break, crack, movement or other adverse issue associated with the tensioned bolt 5.

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PCT/AU2016/000121 (0068] Preferably, each tensioned bolt sensor 44 is affixed to the inferior surface 34 of the protective cover 3.2 .and comprises an electronic trigger 46 that engages when one or more tensioned bolts 5 break and a part of the, or each, tensionvd holt 5 that has broken comes loose or fee. Preferably, the electronic trigger 46 engages when the, or each, part that has broken off comes into contact with the electronic trigger 46.

[0069] Alternatively or additionally, the electronic trigger 46 also engages when the 'tree gap between the head of the broken tensioned bolt 5 and the tensioned bolt sensor 44 is altered or disturbed. This may happen, for example, when the tensioned bolt 5 has cracked or when fatigue alters the shape or geometry of the tensioned bolt 5 prior to actual final failure wherein the head of the tensioned bolt 5 fully breaks away.

[0070] Each tensioned bolt sensor 44 is capable of detecting multiple tensioned bolt 5 breakages. Each sensor 44 is designed and manufactured using resilient materials such that any parts that break off from a tensioned bolt 5 that come into contact with the tensioned bolt sensor 44 do not. affect its sensitivity or performance.

[0071] In an alternative embodiment of the invention, each tensioned bolt sensor 44 will be embedded between the interior surface 34 and exterior surface 36 of the protective cover 32 (not shown). In this arrangement, the interior surface 34 forms a barrier and protects each tensioned bolt sensor 44 from parts that have broken off from tensioned bolts 5. It will be appreciated that each tensioned bolt sensor 44 will be capable of detecting tensioned boh 5 breakages notwithstanding the barrier presented by the interior surface 34.

[(1072] In a farther preferred embodiment, at least one sensing device comprises a slippage detector (not shown) capable of detecting any slippage or other adverse movement of the locking device 1 relative to the position of the end plate 27 _or shaft 42 that the locking device 1 is clamped to.

[0073] It will be appreciated that the, or each, sensing device used in the present invention is not limited io a tensioned bolt sensor 44. In one further preferred embodiment, at least one sensing device comprises a vibration sensor (not shown) capable of detecting and measuring one or more vibrational forces acting on and/or

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PCT/AU2016/000121 experienced by the conveyor pulley 30 and/or a conveyor system in which the conveyor pulley 30 is installed, [0074J In one further preferred embodiment, at least one sensing device comprises a tachometer (not shown) capable of measuring a rotational speed of the conveyor pulley 30 in use in RPM.

[0075] In one further preferred embodiment, at least one sensing device comprises a deformation sensor (not shown) capable of detecting and measuring one or more deformations and-’or deflections to the pulley shaft 42, The pulley shaft deformation sensor preferably operates in conjunction with one or more strain gauges (not shown) affixed to the pulley shaft 42.

[0076] In one further preferred embodiment, at least one sensing device comprises an end plate deformation sensor (not shown) capable of detecting and measuring one or more deformations to an. end plate 27 of the conveyor pulley 30. Preferably, the end plate deformation sensor operates in conjunction with one or more strain gauges (not shown) affixed to the end plate.

[0077] In one further preferred embodiment, at least one sensing device comprises a sensor {not shown) capable of measuring a temperature of the conveyor pulley 30 or a part of the conveyor system in which the conveyor pulley 30 is installed.

[0078] in one further preferred embodiment, at least one sensing device comprises a sensor (not shown) capable of detecting and measuring excessive lubricant present in a region sensor (not shown) of the conveyor pulley 30 or a part of the conveyor system in .which the conveyor pulley 30 is installed, [00791 In one further preferred embodiment, at least one sensing device comprises a particle sensor (not shown) capable of detecting and measuring particle contamination in a lubrication system (not shown) of the conveyor pulley 30, The particle contamination may be capable of detecting and measuring many different forms of particle contamination which may include, for example, metal filings originating from one or

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PCT/AU2016/000121 more bearings, bearing housings anchor bearing accessories attached or near to a bearing housing of the conveyor pulley (including, tor example, a grease labyrinth).

[()080] it will be appreciated that having the, or each, sensing device integrated with the protective cover 32 provides that the, or each, sensing device is in an optima] position for detecting and measuring the relevant physical phenomena, conditions or activities that the relevant sensing device is intended to detect and measure.

[0081] It is not. uncommon for conveyor pulleys to be used at multiple sites after being manufactured, particularly conveyor pulleys that are used at temporary construction and mine sites. Conveyor pulleys may also be transported, often over long distances, between different depots and sites during installation and maintenance operations. hi these situations, it is desirable for conveyor pulley manufacturers and users to be able to identify a conveyor pulley easily so that it can, for example, retrieve the conveyor pulley’s service history, date of manufacture and deployment, or any operational data collected 'live' during operation of the conveyor pulley on-site, etc.

[0082] ft is further object of the present invention to provide a practical and effective means for conveyor pulley users, manufacturers and maintenance providers to identify a conveyor pulley or parts thereof [0083] In a further preferred embodiment of the present invention the protective cover

32, therefore, further comprises an identification means integrated with the protective cover 32, [00841 As shown in Figure 4, the identification means preferably comprises a radiofrequency identification (RFID) tag 52 affixed to the protective cover 32. Preferably, the RFID lag 52 is affixed to the interior surface 34.

[0085] In an alternative preferred embodiment (not shown), the RFID tag 52 is embedded inside the protective cover 32 such that the RFID tag 32 is embedded between the interior surface 34 and the exterior surface 36 of the protective cover 32.

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PCT/AU2016/000121 [0086] The RFID tag 52 has a unique identification (or 'serial') number electronically encoded within the RFID tag 52 that is associated with the protective cover 52 and, therefore by extension, associated with the conveyor pulley 30 that the protective cover 32 is fastened to. The identification number may be read by users of the conveyor pulley (including maintenance personnel) or its manufacturer or repairer to identify the conveyor pulley and, for example, retrieve its service historv and any other items of stored data relating to the conveyor pulley.

[6087] it is possible that objects and materials may come into contact with the protective cover 32 inadvertently during both installation and operation For example, during oper ation materials being transported on the conveyor belt may fall from the belt and hit the protective cover 32 or high pressure wafer may be directed onto the cover during equipment cleaning. The protective cover 32 is, therefore, manufactured from a tough, resilient material.

[0088] The protective cover 32 is also, preferably, manufactured from a nonconductive material owing to the fact that conductive materials can adversely interfere with the electronics used in the, or each, sensing device or any RFID tags 52 and wireless data transmission systems incorporated into the protective cover 32. These components could also corrode if not adequately protected and exposed over long periods to suit and moisture-laden environments.

[0089] The protective cover 32 is preferably made from a Kevlar' based filament material.

[0090] It is also envisaged that the protective cover 32 may be manufactured using an additive manufacturing process such as, for example, 3D printing. In particular, in embodiments of the present invention wherein the, or each, sensing device and any RFID tags 52 and/or wireless data transmission system is embedded between the interior surface 34 and exterior surface 36 of the protective cover 32, a 3D printing manufacturing process will allow these components to be hermetically sealed within the protective cover 32 easily, thereby protecting these components.

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PCT/AU2016/000121 [0091] It is also possible that water may come into contact with the protective cover 32 during use because high salinity water suppression -sprays are often used near to conveyor pulley materia] handling areas. Any water that penetrates the protective cover 32 may damage its internal components including, for example, the electronics used in the, or each, sensing device. The protective cover 32 may., therefore, incorporate O-ring materials disposed at, and between, parts of the protective cover 32 where water and humidity may penetrate such as, for example between the seal that is formed between the protective cover 32 and the end plate 50 of the conveyor pulley 30 when the protective cover 32 is installed.

[0092] Referring to Figure 5, there is shown an alternative embodiment of the conveyor pulley monitoring apparatus 31 according to the present invention. The monitoring apparatus 31 comprises a conveyor pulley locking device protective cover 54 that is installed over, and onto, a locking device 56 used to fasten a conveyor pulley shell 25 to a pulley shaft 60.

[00931 The protective cover 54 comprises an outer cover 62 and an inner cover 64. The outer cover 62 and inner cover 64 arc each, preferably, made from a tough, resilient non-metallic material such as a carbon ora composite carbon and Kevlar based filament material.

[0094] The protective cover 54 further comprises a sensing means which consists of a sensor board 66 capable of detecting a break, crack, movement or other adverse issue associated with one or more tensioned bolts 68 used in the locking device 56. The sensor board 66 is disposed inside a first cavity 70 formed between the outer cover 62 and the inner co ver 64.

[0095] The outer cover 62 serves to protect, the locking device 56 and tensioned bolts 68 from the external environment. The inner cover 64 forms a barrier and serves to protect the sensor board 66 from any tensioned bolts 68, or parts of tensioned bolts 68, that break off while the conveyor pulley 58 is in use.

[0096] .As shown in Figure 6, the sensor board 66 may further comprise an additional protective layer 72 disposed on an exposed surface of the sensor board 66. The

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PCT/AU2016/000121 protective layer 72 serves to protect the sensor board 66 and electronic components thereon from moisture.

[0097] The protective cover 54 further comprises a bolt guide layer 74 which defines a second cavity 76 of the protective cover 54. The second cavity 76 is adapted to enclose, at least in part, the tensioned bolts 68 of the locking device 56 during use.

10098] As most clearly shown in Figure 6, the second cavity '76 comprises an annular tapered hole 78. In the event that a tensioned bolt 68 breaks, the tapered hole 78 serves io guide the broken tensioned bolt 68, or parts thereof, towards the direction of the sensor board 66 until they come into contact with, and are stopped by, the inner cover 64.

[0099] The sensor board 66 comprises suitable electronic components capable of detecting a movement of the tensioned bolt 68 towards the sensor board 66 and may comprise, for example, an inductive metal sensor.

[00100] As an alternative to using an inductive metal sensor, the sensor board 66 may comprise an ultrasonic, optical, capacitive, magnetic. Hall-effect or other proximity or distance-based sensor.

[()0101] Referring to Figure 7,. there is shown, in schematic form, an exemplary representation of the sensor board 66 used in the embodiment of the present invention shown, in Figures 5 and 6. The sensor board 66 comprises a plurality of sectors 80 arranged in a daisy-chain configuration about a common centre io form a substantially circular shape. The sensor board 66 is adapted such that it fits inside the first cavity 70 of the protective cover 54.

[001(12] Each sector 8(1 comprises a sensing region 82 and a control region 84. Each sensing region 82 comprises sensing means used by the protective cover 54. Each control region. 84 is adapted to receive and store data obtained by the respective sensing means.

[00103] Further, each of the control regions 84 may be adapted to communicate with one another and/or with peripheral devices, such as a handheld device operated by a

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PCT/AU2016/000121 serviceperson, including by wireless communication to send and-'or receive data obtained by the sensmg means, on an intermittent or continuous signal basis.

[00104] As an alternative to having multiple separate control regions 84. the protective cover 54 may comprise a central microcontroller that communicates with, and controls, each o f the sensing regions 82.

[00105] The outer cover 62, sensing board 66 and inner cover 64 are, preferably, each releasably attachable from the protective cover 54 so as to facilitate ease of installation and mainteftanee of the protective cover 54.

[00106] As most clearly shown in Figure 6, the outer cover 62. may additionally comprise a groove 86 in which may be disposed an O-ring (not shown.) made of rubber or similar material. The O-ring forms a seal between the outer cover 62 and the pulley shaft 60 when the protective cover 54 is installed to prevent ingress of water and/or humidity during operation.

[00107] Further, a lower section of the boh guide layer 74 may also comprise a groove 88 in which may be disposed an O-ring, made of rubber or similar material, to form a seal between the boll guide layer 74 and the end plate 27 of the pulley shell 25 when the. protective cover 54 is installed.

[00108] The seals that are formed between the cover 32 and end plate 27 via groove 88, the cover 32 and shaft (42, 60) via groove 86 and the battery holder door and cover mating faces (not shown) are, preferably, achieved using. Quad section seals to reduce the risk of losing the seal, during maintenance or battery change over. These types of seals are preferable to the normal Ο-Ring shape seals as they are more permanently affixed to the groove and therefore, the risk of missing/losing them during any maintenance or changeover will be reduced. Ensuring the seals remain in the grooves is important as the absence of seals will increase the risk of dust and humidity ingress and associated malfunctions that can arise when there is no seal protection. Furthermore, the mating faces between cover and end plate/shait (27 and 42/60) can be further sealed with an additional layer of automotive style 'Sikaflcx* silicone’ or any other similar products.

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PCT/AU2016/000121 [00109] Referring to Figure 8, there is shown a schematic drawing of electronic components comprised in an electronic architecture 9(1 utilised in the protective cover 54, I’he architecture 90 comprises a system battery 92, battery management unit 94 and sensing devices 96. For convenience, the protective cover 54 in which the architecture 90 is implemented comprises a single central microcimtroller 98.

[00110] The system battery 92. is the principal power supply for the sensor board 66 of the protective- cos er 54, To facilitate installation and ease of removal, the system battery 92 is. preferably, housed inside a dedicated battery compartment. (not shown) within the protective cover 54. It is preferred that the distance between the sensor board (66) and the battery is at least the same distance as that between the unbroken bolt head and the sensor board (66), This will reduce the chances of the sensor board (66) misreading the battery (due to metallic parts of battery or holder) instead of the bolt head(s). The protective cover (54) can have a pocket for positioning the battery and holder inside with a sealed door to ease access from- the outside during maintenance· and battery change over. This pocket can also accommodate other connecting ports such as a USB port for connecting to the microcontroller.

[0011Γ] The system battery 92 supplies electrical power to the battery management unit 94 via a single power rail 100, The battery management unit 94, m turn, produces and supplies appropriate voltage and electrical currents to all other components of the protective cover 54 that require electrical power, including to the sensing devices 96 via a sensor power line 102, to the microcontroller 98 via a microcontroller power line 104 and to a communication means 106 via a oommumeation power line 108.

[00112] Ίο maximise the life of the system battery 92, the battery management unit 94 operates, in conjunction with the microcontroller 98 via a microcontroller control line 110, to schedule the supply of power to the powered components of the protective cover 54, including the sensing devices 96 via a sensor control line 112. The battery management unit 94 and microcontroller 98 ensure that power is only supplied when the conveyor pulley 30 is operating and when the protective cover 54 is required to actively monitor the conveyor pulley 30.

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PCT/AU2016/000121 [00113] The microcontrolier 98, preferably, comprises embedded code that implements a real time calendar for activating and deactivating the power supply and powered components of the protective cover 54 according to pre-determined wake up and maintenance intervals.

[00114] The battery management unit 94, in conjunction with the microcontroller 98 and a communications control line 114. additionally reports the battery charge and status to one or more peripheral devices via. the communication means 106, which may comprise a wireless communication means, enabling maintenance and services personal to monitor the battery. The microcontroller 98 may also access a pre-determined battery life schedule from a remote network location via the communication means 106, which the microcontroller 98 uses to raise alert notifications when the system battery 92 needs to be replaced prior to a predicted power failure.

Γ00115] Referring to Figure 9(a). there is shown a schematic diagram of an exemplary configuration of electrical components comprised in an inductive metal sensor '116 used in the sensor board 66. The inductive metal sensor 116 comprises a spiralled coil detection antenna 118 formed, preferably, using a copper track on the sensor board 66.

The antenna 118 is positioned and aligned in the sensor board 66 such that it may accurately detect when a particular tensioned bolt 68, or parts thereof, have broken off and moved towards the direction of the inductive metal sensor 116.

[00116] The inductive metal sensor 116 further comprises a driver circuit 120 and driver circuit gate 122 which communicate with the microcontroller 98 and/or adjacent inductive metal sensors when, as shown in Figure 9(b). a plurality of sensors are arranged on the sensor board 66 in a daisy-chain configuration.

[0()117] 'The microcontroller 98 has management software embedded therein for dri ving the components of the architecture 90.

[00118] The management software includes a calibration routine which establishes existing tensioned boll 68 positions and the breakage thresholds required to enable each sensor driver circuit 120 to accurately detect tensioned bolt 68 breakages during subsequent use. The calibration routine, preferably, establishes the necessary thresholds

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PCT/AU2016/000121 and tolerances using a learning algorithm, in conjunction with empirical data, and, once calculated, stores the values to non-volatile memory within the microcontroller 98.

[00119| The calibration routine is executed prior to the first use of the protective cover 54 and subsequently if, for example, the protective cover 54 needs to be re-assembled for system maintenance purposes.

[001201 Referring to Figure 10, there is provided a schematic flow diagram showing procedural steps 124 that are executed by the management software once calibration, has been performed and completed.

[00121J As disclosed above, to preserve the life of the system battery 92 and maximise time interval between charges, the microcontroller 98 and battery management unit 94. together, ensure that power is only supplied to the powered components of the protective cover 54j including the sensor board 66, when the conveyor pulley 30 is operating and/or requires active monitoring. The management software, therefore, ensures that the powered components are, tor most of the time, left in a powered-down idle state.

[()()122] When the management software determines, according to its pre-determmedschedule, that the protective cover 54 is required to wake up and enter an active state, the software executes a system initialisation procedure 126 before executing a power up procedure 128 to toggle the supply of power to the sensor board 66 and other powered components, as required.

[00123] The software then executes an evaluation procedure 130 pursuant to which the current positions of all tensioned bolts 68 are recorded. The software uses this data, in conjunction with the breakage threshold parameters acquired during calibration, to determine whether or not any boh breakages have occurred.

[{)0124] The software then executes a communications procedure 1'2 pursuant to which the recorded values and results obtained during the evaluation procedure 130 are transmitted, via the communication means 106, to one or more peripheral devices which, may comprise, for example, a mobile telephone, tablet or laptop. A peripheral device may also comprise, by way of further example, a relay station that relays the informatmu

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PCT/AU2016/000121 to a central controller for display via a Supervisory Control And Data Acquisition (SCADA) system.

[00125] The software then executes a system power down procedure 134 before reentering its power saving mode 136. A scheduling alarm routine 138 executed by the management software keeps the system in an idle state before the next set of active readings need if¹ be taken according to the pre-determined schedule.

[00126] The pre-determined schedule may be stored in non-volatile memory in the m icrocont roller 98.

[00127] In the event that, a bolt breakage is detected during the evaluation procedure 130. the management software records this, along with a timestamp, to non-volatile memory within the microcontroller 98 so that the status is latched and may not be reset unless and until the relevant tensioned bolt 68 has been replaced and a human operator has reset the ηόη-volatile memory, [00128] The software may be configured so that it detects, records and reports alternative levels of tensioned bolt 68 failures; for example, the software may implement a warning level failure for when only a single tensioned bolt 68 has failed, and a critical level failure for when a series of tensioned bolts 68 have failed.

[00129] Modifications and variations as would be apparent io a skilled addressee are deemed to be within the scope of the present invention.

Claims

1. A monitoring apparatus for a conveyor pulley, wherein the conveyor pulley is fastened to a pulley shaft using a locking device, the monitoring apparatus comprising sensing means that:

are integrated into a protective cover of the locking device; and comprise at least one bolt detector, the or each bolt detector being adapted to detect a break, crack, movement or adverse issue associated with a tensioned bolt of the locking device.

2. The monitoring apparatus according to claim 1, wherein the sensing means is integrated into a protective cover of the locking device comprising an exterior surface and an interior surface, the interior surface defining an internal area of the protective cover.

3. The monitoring apparatus according to claim 2, wherein the sensing means are disposed in the internal area of the protective cover.

4. The monitoring apparatus according to claim 2, wherein the sensing means are embedded in between the exterior and interior surfaces of the protective cover.

5. The monitoring apparatus according to any one of the preceding claims, wherein the, or each, bolt detector is disposed substantially opposite to a tensioned bolt of the locking device.

6. The monitoring apparatus according to claim 5, wherein the, or each, bolt detector comprises an electronic trigger that engages when a tensioned bolt of the locking device, or a part thereof, breaks off during use of the conveyor pulley and comes into contact with the bolt detector.

7. The monitoring apparatus according to any one of claims 1 to 4, wherein the, or each, bolt detector comprises an electronic trigger that engages when a shape or geometry of a tensioned bolt of the locking device changes due to cracking or fatigue of the tensioned bolt during use of the conveyor pulley.

AMENDED SHEET

IPEA/AU

PCT/AU2016/000121 Received] 8/10/2016 24

8. The monitoring apparatus according to any one of the preceding claims, wherein the monitoring apparatus further comprises an identification means for identifying the conveyor pulley or a part thereof.

9. The monitoring apparatus according to claim 8, wherein the identification means comprises a radio-frequency identification tag (RFID).

10. The monitoring apparatus according to claim 1, wherein the sensing means is integrated into a protective cover comprising an outer cover, an inner cover and a sensor board, and wherein:

the sensor board has the sensing means attached thereto and is disposed inside a first cavity formed between the outer and inner covers of the protective cover; and the inner cover of the protective cover is configured to protect the sensor board from a tensioned bolt of the locking device, or a part thereof, that breaks when the conveyor pulley is in use.

11. The monitoring apparatus according to claim 10, wherein the protective cover further comprises a bolt guide layer that defines a second cavity enclosing, at least in part, one or more tensioned bolts of the locking device.

12. The monitoring apparatus according to claim 11, wherein the second cavity comprises an annular tapered hole adapted to guide towards the sensor board a tensioned bolt, or a part thereof, that breaks off during use of the conveyor pulley.

13. The monitoring apparatus according to any one of the preceding claims, wherein the sensing means comprises at least one inductive metal sensor.

14. The monitoring apparatus according to any one of the preceding claims, wherein the sensing means is integrated into a protective cover comprising a groove having an O-ring disposed therein, wherein the O-ring forms a seal between the protective cover and the pulley shaft.

15. The monitoring apparatus according to claim 14, wherein the protective cover comprises a further groove having an O-ring disposed therein to form a seal between the protective cover and an end plate of a pulley shell of the conveyor pulley.

AMENDED SHEET

IPEA/AU

PCT/AU2016/000121

Received? 8/10/2016

16. The monitoring apparatus according to any one of the preceding claims, wherein the monitoring apparatus further comprises a wireless data transmission system for wirelessly transmitting data collected using the sensing means to a peripheral device.

17. The monitoring apparatus according to claim 16, wherein the wireless data transmission system uses Bluetooth® technology.

18. The monitoring apparatus according to any one of the preceding claims, wherein the sensing means comprises at least one vibration sensor.

19. A protective cover for a locking device, the locking device being adapted to fasten a conveyor pulley to a pulley shaft, wherein the protective cover comprises sensing means that:

are integrated into a protective cover; and comprise at least one bolt detector, the or each bolt detector being adapted to detect a break, crack, movement or adverse issue associated with a tensioned bolt of the locking device.