CONVEYOR BELT TRACKING IDLER AND SYSTEM
FIELD OF THE INVENTION THIS INVENTION relates to a conveyor belt tracking idler and system
particularly suited to use in an endless belt conveyor system employing tracking
idlers at strategic positions .
BACKGROUND TO THE INVENTION
It is common practice to use tracking idlers in an endless belt conveyor
system to automatically correct belt misalignment. Common tracking idlers employ
a frame carrying rollers and being able to pivot to maintain proper tracking. The
present invention has as its primary object to provide a useful alternative to present
tracking idlers.
OUTLINE OF THE INVENTION
In one aspect therefore the present invention resides broadly in a conveyor
belt tracking idler having a pivot mounting and including a roller and brake means
able to brake the roller laterally of said pivot mounting in response to belt
misalignment to return a belt to proper tracking, the brake means comprising a
laterally positioned belt engageable brake actuator and a brake communicating with
the brake actuator so that as the belt engages the brake actuator, the brake is
applied to the roller causing the belt to push the braked roller in the direction of
belt travel and thereby correcting the misalignment.
The brake means preferably employs a brake actuator in the form of an
actuator roller, a linkage and brake pad, the linkage communicating a braking force
to the brake pad, the brake pad being operably configured to engage a brake
surface on the roller to brake the roller when moved from an "unbraked" position
to a "braked" position.
Preferably, the brake means includes a bias means to aid return of the
actuator to an unbraked position. The bias means may be a spring, counterweight
or the like. Where a counterweight is employed it is preferably mounted to the
actuator at an offset about a pivot so that the actuator and counterweight have an
equilibrium position corresponding to the unbraked position.
The actuator rol ler is typical ly a tapered rol ler provid ing a ramp surface over
which the belt travels to actuate the brake means.
The brake pad is typically swivel mounted or pivotal ly mounted to improve
pad to brake surface contact.
The brake surface is typically at an end of the roller. Typically the brake
surface comprises an annular brake surface positioned on the end of the roller. In
one preferred form the brake surface comprises a brake disc fitted to an end of the
roller. Typically, the brake disc is mounted to the roller end by means of a sleeve,
the sleeve and disc having co-operating key and key-way and being retained in
place on a standard roller by a shaft adapter extending the existing shaft. Thus
existing commercially available rollers may be fitted out with the brake disc. The
brake disc is typically cast iron with anti-glazing grooves and cooling holes.
Preferably, the linkage comprises a lever assembly and a lever drive link
constrained to move in a straight line, the lever assembly having a lever connected
to the brake pad, a fulcrum and a lever arm, the lever drive link having opposite
ends and being connected at one end to the actuator and its other end being
connected to the lever arm, the fulcrum being located between the pivotal
connection of the lever drive link and the brake pad to provide a force ratio of
actuator to breaking force exceeding 1 :1 and preferably at least 1 :3.
The roller may be a single roller retained in a frame adapted to pivot in
response to one side of the rol ler being braked, brake means are typical ly employed
at both ends of the roller, one brake means being used to correct misalignment in
one lateral direction and the other brake means being used to correct misalignment
in the opposite direction. However, if the at the position in the system,
misalignment is predictably in one direction only, only one end of the roller needs
to have a brake means. Typically, this arrangement is employed in a return run
idler assembly where the belt is in a flat belt configuration.
The roller may be a lateral one or one of a lateral pair of a multiple roller
idler assembly. For example, the multiple roller idler assembly may be a flat belt
return run idler or forward run idler assembly configured for a trough belt. In a case
of a trough belt run assembly, one or more lateral rol lers may be employed, one or
more of the lateral rollers may be braked. Typically, pairs of rollers are employed
bilaterally, the assembly being in a symmetrical arrangement with the pairs being
positioned either side of a central roller and there being bilateral brake means
employed, each brake means comprising at least one actuator roller, a linkage and
a brake, the brake being operative to engage brake surfaces on each roller of the
respective roller pairs by reason of a misaligned belt engaging the actuator roller
corresponding to the brake means of that pair.
The brake means typically includes adjustable means so that the sensitivity
of the brake means may be adjusted. In the case of an actuator roller the position
of the actuator roller may be adjusted laterally. In another embodiment, the
inclination of the actuator roller may be adjusted. In still another embodiment the
lateral position and inclination of the actuator roller may both be adjustable.
BRIEF DESCRIPTION OF THE DRAWINGS
In a preferred form the rollers are mounted on a slew frame adapted to slew
about a vertical axis.
In order that the present invention may be more readily understood and be
put into practical effect, reference will now be made to the accompanying drawings
which illustrate preferred embodiments of the invention and wherein:
Figure 1 is a perspective view of a typical idler according to the invention;
Figure 2 is a plan view of the idler of Figure 1 ;
Figure 3 is a front elevation view of the idler of Figure 1 ;
Figure 4 is a perspective view from the showing one end of the idler of
Figure 1 ;
Figure 5 is a front elevation view of one end of the idler of Figure 1 ;
Figure 6 is a front elevation view of the idler of Figure 1 with one roller
removed to illustrate the idler in the "unbraked" position;
Figure 7 is a view similar to Figure 6 illustrating the idler in the "braked"
position;
Figure 8 is a part perspective view from the front of the idler of Figure 1 with
one roller removed to illustrate the lateral adjustability of the actuator roller;
Figures 9 and 10 are schematic drawings illustrating application of the
invention to a flat return belt run in an endless belt conveyor;
Figures 1 1 and 12 are schematic drawings illustrating application of the
present invention to a trough run in an endless belt conveyor;
Figures 13 and 14 are respective exploded and assembled views illustrating
a preferred roller and brake drum assembly suited to a tracking idler according to
the invention;
Figure 15 is a perspective view similar to Figure 1 but in this case illustrates
an idler employing the roller arrangement of Figures 13 and 14, a tapered actuator
roller, alternative brake lever and swivel mounted brake pads;
Figure 16 is a part perspective view illustrating one end of the idler of Figure
15; and
Figure 1 7 is a front elevation view of the idler of Figure 1 with one roller
removed showing the actuator roller, counterweight and brake means including the
modified brake lever arrangement.
METHOD OF PERFORMANCE
Referring to the drawings and initially to Figures 1 to 3 there is illustrated an
idler roller assembly 10 including a slew frame 1 1 which are supported by a
bearing assembly 12 on a base frame 13, as depicted an arrangement of rollers
includes a central roller 14 and opposed pairs of rollers shown as side rollers 15,
16, 1 7 and 18, respective actuator rollers 19 and 20 are positioned between the
pairs of side rollers and form a part of a brake means. The brake means operates
upon a belt engaging either of the actuator rollers 19, 20 depending upon the
direction of belt misalignment to apply brake pads 21 and 22 to the rollers 15 and
16 or brake pads 23 and 24 to the rollers 1 7 and 18.
Depending upon which brake pads are engaged with which rollers the
rollers so engaged will be slowed or brought to a stop beneath the belt, thus rather
than roll on the rollers the side of the belt concerned will frictionally engage the
rollers creating a friction force opposite the direction of travel of the belt across the
rollers. The result of this force will be to cause the slewing frame 1 1 to slew about
the bearing assembly 12 in the direction of belt travel and thus cause the belt to
move in a direction opposite the direction of misalignment and thereby reinstate
proper tracking.
Referring to Figures 4 to 7, a typical brake means and its operation will be
described in greater detail. Where appropriate like numerals have been used to
illustrate like features as those features are depicted in Figure 1 to 3. As can be
seen, the brake means comprises an actuator roller, for example 19, and a linkage
25 including an arm 26 pivotally coupled at 27 to the shaft 28 carrying the actuator
roller 19, the other end of the arm 26 is pivotally coupled at 29 to a crank assembly
30. The crank assembly 30 comprises crank arm 31 and crank rod 32 journal led
in bearings 33 and 34, with output crank arms 35 and 36 carrying the brake pads
21 and 22. Like numerals have been used to illustrate like features in relation to
the actuator roller 20 and the views shown consistent with Figures 1 to 3.
Figures 6 and 7 show the actuator rol ler 20 and its disposition in Figure 6 as
it would be when the brake pads 21 and 22 are in an "unbraked" position, whereas
Figure 7, shows the typical position when the brake pads are in a "braked" position,
the belt having become misaligned to the extent that the actuator roller 20 in Figure
7 has been depressed by the edge of the conveyor belt (not shown) to the position
illustrated in Figure 7.
Referring to Figure 8, the actuator roller 19 is illustrated in the "unbraked"
position and Figure 8 clearly shows how the actuator rollers are mounted. As can
be seen the actuator roller is mounted on a mounting body 37 which is disposed
between mounting rails 38 and 39 formed as part of the slewing frame 1 1 . The rails
38 and 39 include mounting holes 40 so that the position of the mounting body 37
can be adjusted laterally relative to the position of a belt on the slewing frame 1 1 .
The arm 26 can include a turn buckle arrangement or other form of adjustment so
that the length of the arm 26 can be varied to suit the position of the actuator roller
in its selected grouping of holes 40. As can be seen in the illustrated embodiment
of Figure 6, mounting body 37 is positioned utilising three holes 40 at any one
time. It will be appreciated that the actuator roller position can be adjusted for
different belt positions and simply by adjusting the angle between the arm 26 and
the shaft 28 inclination of the actuator roller in each case may also be adjusted.
The two forms of adjustment may be used individually or in combination to vary
sensitivity.
Figures 9, 10, 1 1 and 12 show application of the present invention to a flat
return run in Figures 9 and 10 and a trough run arrangement as illustrated in Figures
1 1 and 12. In each case the slew frame only is illustrated, the base frame is not
shown connected to the slew frame. Figure 9 illustrates a belt 41 in an aligned
position and the same belt is shown in a misaligned position in Figure 10, showing
the actuator roller 42 applying the brake 43 to the end of the roller which in turn
as described previously will cause the frame to slew and the belt to be realigned.
A belt 44 is illustrated in Figure 1 1 in an aligned position and moved to a
misaligned position in Figure 12 thus engaging the actuator roller 45 and causing
the brake 46 to be engaged causing the frame to slew and the belt to return to the
aligned position of Figure 1 1.
While the braking surface may simply be an end of a roller of any workable
configuration it is preferable to utilise standard commonly available rollers modified
to bets effect. To this end the rollers are more preferably made from standard rollers
fitted out as shown in Figures 13 and 14. The standard roller 47 has a stub 48 which
is keyed to an adapter 49 which projects through hole 50 in brake disc 51 . A sleeve
52 is used to connect the brake disc to the roller. The sleeve is retained in place by
screws as shown. The brake disc is keyed to the sleeve to align hole where the
screws are used to secure the brake disc to the sleeve. The brake surface 52 has
anti-gazing grooves 53 and cooling holes 54.
Figures 15-17 illustrate the rollers of Figure 14 employed in an alternative
arrangement to the embodiment of Figure 1. The rollers shown are again mounted
on a slewing frame 55 which is able to slew about an axis vertical and centred on
the middle roller 56. The main frame 57 is fixed. A tapered actuator roller 58 is
employed on each side. Reference will be made to Figures 16 and 1 7 it being
understood that the same arrangement is employed on the other side. The actuator
roller 58 has a ramp surface 59 that intersects a plane tangential to the pair of rollers
47 and along which the belt would travel as it tracks off. The actuator roller 58 is
mounted on an axle 60 which projects from a counterweight 61 which pivots about
62 so the counterweight as in the previous embodiments biasses the roller 58 to the
position shown. When the actuator roller is engaged by the belt the drive link 63
applies a force from the belt via actuator roller to the lever arm 64 which in turn
applies about a 3:1 force through the fulcrum 65 to the levers 66 which carry brake
pads 67. The brake pads have pivot mountings 68 to ensure even braking force
over the surface of the pads.
Whilst the above has been given by way of illustrative example of the
present invention many variations and modifications thereto will be apparent to
those skilled in the art without departing from the broad ambit and scope of the
invention as set out in the appended claims.