WO2016019431A1

WO2016019431A1 - Conveyor roller monitoring apparatus, system and method

Info

Publication number: WO2016019431A1
Application number: PCT/AU2015/050435
Authority: WO
Inventors: Maxwell Olgun Arif
Original assignee: Ezifix Mining Solutions Pty Ltd
Priority date: 2014-08-04
Filing date: 2015-08-04
Publication date: 2016-02-11
Also published as: AU2015100473A4

Abstract

A conveyor roller (10) for a conveyor system has a cylindrical roller body (12) supported for rotation about a central axle (14) having an axis of rotation (16). A recess (20) extends into the end of the axle. A conveyor condition monitoring device (22) is mounted within this recess. The device has a battery, a transmitter and at least one sensor, such as a vibration sensor, an accelerometer and/or a temperature sensor. The transmitter can optionally transmit a unique code identifying the particular roller from other rollers. The device can have an RFID chip to transmit data relating to the sensed condition of the roller. The can be a module that is inserted into the recess for use, and may be removed when the module fails or the battery needs replacing. The device can form part of a system including remote monitoring equipment which receives roller condition signals from the device. Maintenance of the roller can be conducted based on the data receive from the roller condition monitoring apparatus.

Description

CONVEYOR ROLLER MONITORING APPARATUS, SYSTEM AND METHOD

FIELD OF THE INVENTION

[0001 ] The present invention relates to a monitoring apparatus, system and method for a roller for a conveyor belt system, such as an endless belt conveyor system for transporting bulk materials e.g. iron ore, coal or grain.

BACKGROUND TO THE INVENTION

[0002] Conveyor systems typically incorporate many rollers to support a conveyor belt. There can be many thousands of rollers in a lengthy conveyor system, and typically rollers are provided to support and guide the belt and the load thereon, and on return rollers for the unladed return portion of the endless belt after unloading.

[0003] The rollers are suspended by the support frames, typically with two outermost rollers, one each side, inclined downwards towards the middle of the conveyor belt, and at least one lateral roller between the two inclined rollers, thereby creating a general 'bowl' shape to support the belt and to help confine the material conveyed by the conveyor system towards the centre of the belt and thereby help to avoid side spillage.

[0004] Such rollers generally have a central axis about which the cylindrical body of the roller rotates on bearings at each end thereof.

[0005] As the bearings and/or roller surface wear, the roller is at risk of failing. A failed roller can cause damage to the conveyor belt, and may result in complete failure of the conveyor.

[0006] Systems have been devised to assist in early detection of roller failure. For example, WO 2012/122597 describes a roller monitoring system having vibration detection adjacent the central axis within the body of the roller, and a transmitter to transmit signals.

[0007] It has been found desirable to provide an improvement to better facilitate early detection of risk of roller failure of a conveyor system.

SUMMARY OF THE INVENTION

[0008] With the aforementioned in mind, an aspect of the present invention provides a monitoring apparatus for a roller of a conveyor system, the apparatus including a roller monitoring device for mounting to the roller at or adjacent a central axis thereof.

[0009] Preferably the monitoring apparatus includes detection means to detect at least one physical characteristic of or affecting the roller. Such detection means may include one or more sensors, such as at least one strain gauge, at least one accelerometer and at least one temperature sensor.

[0010] The one or more strain gauges may be used to weigh material transported by the conveyor system. For example, material loaded onto the conveyor belt will be detected as a strain value by the at least one strain gauge, preferably mounted to the axle shaft of the roller.

[001 1 ] Such detected strain values are provided to the components/module at the end of the roller axle, and then transmitted remotely to a monitoring location or read directly by a scanner used by personnel.

[0012] Preferably the detection means includes at least one component thereof mounted within or to an end of a central axle of the roller. [0013] More preferably, the at least one component may be a discrete device or module including at least one of a battery to power the device, a sensor, electronic circuitry., a transmitter to transmit signals to a remote location and a processor.

[0014] The at least one component may be sealed (e.g. 'potted') in protective material in a recess or opening in the end of the axle of the roller. Such 'potting' material may be or include a resin.

[0015] Alternatively, the at least one component may be provided within a housing of a discrete module that attaches to or is inserted into a recess in the roller axle or around the end of the roller body adjacent the axle. The at least one component may be sealed in the housing or other sealing against ingress of moisture and/or dirt.

[0016] For temperature stability, the at least one component may have a relatively small contact point with metal of the axle shaft of the roller. This helps to reduce unwanted heat transfer to the at least one component which might otherwise distort temperature readings or detection in an absolute or rate of change of temperature.

[0017] Power for the component(s) may be supplied by at least one battery associated with the device or power may be supplied by rotation of the roller during operation of the conveyor system. Alternatively, acceptable levels of vibration (normal vibration) may be farmed through energy harvesting to power the device.

[0018] The device may detect an increase in temperature above ambient temperature and/or vibration above a normally accepted level of vibration as an early indicator of potential failure of the roller bearings. [0019] Deterioration of the roller's condition can be monitored in real time, and preventative maintenance scheduled based other rate of deterioration of the roller bearings.

[0020] The monitoring apparatus may include a unique identifier for each roller, such as a barcode, number or code in an RFID chip. Each roller can therefore be identified uniquely from all of the other rollers, and not just as one unknown roller on a roller frame. Thus, each roller can be logged to not only a particular frame, but also a particular position in the frame.

[0021 ] The unique identifier can be read by personnel with suitable hand held reading equipment, such as a barcode scanner or smartphone/tablet via a camera and an application, and the condition of the roller monitored directly.

Alternatively, the apparatus can wirelessly transmit its location and condition to a remote location, such as a manned monitoring station.

[0022] Providing monitoring at roller level, rather than just frame level, avoids needing to change good rollers in a frame or avoids the additional time taken to identify a failing roller amongst a number of rollers on the frame or on adjacent frames. Thus, monitoring is improved and risk of roller failure is alleviated.

[0023] For example, if temperature is detected as exceeding a threshold level, a warning signal can be sent to monitoring location. Alternatively, the monitoring location can observe temperature and/or vibration signals in real time and plan maintenance based on rate of change or absolute change in roller

temperature/vibration.

[0024] Preferably the roller includes at least one strain gauge mounted to the axle shaft. The at least one strain gauge may send strain related signals to the at least one component in or at the appropriate end of the roller axle. [0025] Detected strain can be used an indicator of bearing failure or wear of the roller outer body surface, thereby acting as an early indicator of roller failure.

[0026] A further aspect of the present invention provides a roller condition monitoring module for mounting to or in an end of an axle of the roller.

[0027] Another aspect of the present invention provides a conveyor roller condition monitoring apparatus, including a conveyor roller monitoring device providing a unique identifier to identify a conveyor roller to which the device is mounted or is incorporated.

[0028] A further aspect of the present invention provides a conveyor roller condition monitoring apparatus, including a conveyor roller monitoring device including at least one sensor including at least one of a vibration sensor, an accelerometer and a temperature sensor to sense a change in at least one of a respective sensed vibration, acceleration and temperature characteristic.

[0029] The conveyor roller condition monitoring apparatus may include a transmitter to transmit a signal relating the unique identifier to a remote location and/or the conveyor roller condition monitoring apparatus may include a transmitter to transmit the respective at least one sensed vibration, acceleration and temperature characteristic to the remote location.

[0030] Preferably the conveyor roller condition monitoring apparatus may include a conveyor roller monitoring device providing a unique identifier to identify a conveyor roller to which the device is mounted or is incorporated.

[0031 ] Preferably the conveyor roller condition monitoring apparatus may include a conveyor roller monitoring device including at least one sensor including at least one of a vibration sensor, an accelerometer and a temperature sensor to sense a change in at least one of a respective sensed vibration, acceleration and temperature characteristic. [0032] The conveyor roller condition monitoring apparatus may include a transmitter to transmit a signal relating the unique identifier to a remote location.

[0033] The conveyor roller condition monitoring apparatus may include the transmitter to transmit the respective at least one sensed vibration, acceleration and temperature characteristic to the remote location.

[0034] A further aspect of the present invention includes a method for monitoring a plurality of conveyor rollers for an endless conveyor system, the method including the steps of: providing each said conveyor roller with an electronic conveyor roller monitoring device, and obtaining from one or more said rollers unique identification data identifying each said conveyor roller.

[0035] The method may include obtaining from one or more of the conveyor rollers information providing an indication of one or more specification

characteristics of the conveyor roller(s).

[0036] The specification characteristic(s) may include size and/or type of conveyor roller for each said roller.

[0037] The information relating to the size of each said conveyor roller may include one or more of diameter, width or length specification.

[0038] The information relating to the type of conveyor roller may preferably include roller material.

[0039] The method may include conducting an audit (preferably of the presence and optionally the type and/or specifications of the rollers) by remotely communicating with each of the plurality of conveyor rollers and receiving from each of the conveyor rollers the unique identification data, and compiling the audit utilising the unique identification data. [0040] Each of the conveyor rollers may include at least one sensor, and the method may include, with at least one of the conveyor rollers mounted in use in the endless conveyor system, the at least one conveyor roller sensing that vibration, sound or temperature, or a combination of two or more thereof, at the respective at least one roller meets or exceeds a respective vibration, sound and/or temperature first threshold, and alerting a conveyor roller condition monitoring system of the vibration or temperature or sound or a combination of two or more thereof meeting or exceeding the respective first threshold(s).

[0041 ] The method may include entering the said conveyor roller(s) into a maintenance schedule if the sensed temperature and/or vibration meets or exceeds the respective first threshold(s).

[0042] The maintenance schedule may include conveyor roller condition monitoring reporting if the sensed temperature or vibration is at or above the respective first threshold(s) but below a higher respective vibration and/or temperature second threshold.

[0043] Preferably, monitoring of the roller condition between the first and second respective thresholds includes monitoring for change in one or more of sensed temperature, sound or vibration.

[0044] Preferably, when the second threshold is met or exceeded, a status indication is provided that the respective conveyor roller(s) need(s) prompt or urgent replacement.

[0045] Each said conveyor roller may include electronics having a sleep mode whereby, after a period of non-use, the respective conveyor roller electronics enter a sleep mode to conserve battery power, and, when a communication is received by the electronics, the electronics come out of a sleep mode in order to communicate data. [0046] The method may include each said conveyor roller providing data to a client system when awoken from a sleep mode or during use when interrogated by a remote communication device or system.

[0047] Each said conveyor roller may provide said data to a wireless gateway communicating with the client system.

[0048] A further aspect of the present invention provides a conveyor roller monitoring system including a plurality of conveyor rollers, each conveyor roller including electronics with at least one sensor for monitoring at least one condition or specification characteristic of the respective roller, and data output means to send data relating to the condition or specification characteristic, each said conveyor roller sending said data to a respective data gateway communicating with a conveyor roller condition monitoring or reporting system.

[0049] Each said conveyor roller of the system may include said at least one sensor for sensing one or more of vibration, sound or temperature.

[0050] The system may be integrated to communicate with a client data system.

[0051 ] The data stored on each roller, such as the unique identification data relating to that roller or sensor parameters or thresholds etc., may be checked, modified or updated or calibrated remotely, such as by interrogation from a remote communication device directly to the roller in question or via the data gateway(s). Thus, a roller may be configured or reconfigured to suit its

application and location. For example, for high prevailing ambient temperatures, the sensor(s) may be calibrated to report on elevated temperatures above those of more mild ambient temperature locations.

[0052] The microchip inside the shaft or shaft end, coupled with the ability to communicate to a remote device or system, the ability to monitor inventory via the microchips, ability to monitor the full mine site rollers and change them from a single point makes the present invention particularly useful to mine site operators.

[0053] Furthermore, the ability to add on any other information on to or update or calibrate the microchip at a later date as required is particularly advantageous

[0054] It will be appreciated that the embodiments of the present invention do not just simply monitor and report sensed conditions, but as a reporting system actually alerts the operator to the need or impending need to replace the roller or at least continue to monitor the roller more closely. The operator is prompted to act and make maintenance decisions by acting upon the signal and effect the changes remotely.

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] One or more embodiments of the present invention will hereinafter be described with reference to the accompanying Figures, in which:

[0056] Figure 1 shows a general arrangement of a conveyor system with a conveyor belt supported on rollers in support frames.

[0057] Figure 2 shows an idler roller support applicable to the conveyor system of Figure 1 .

[0058] Figure 3 shows a side view of a portion of a conveyor roller with axle end mounting and an enlarged sectional view of a sensing module mounted in the end of the axle shaft, according to an embodiment of the present invention. DESCRIPTION OF PREFERRED EMBODIMENT

[0059] Figure 1 shows a general arrangement of a conveyor system 1 with an endless conveyor belt 2 supported on a number of idler roller support frames 3.

[0060] Stringers 4 support the fixed idler roller support frames. Each support frame has a number of idler rollers 5 directly supporting the belt. The rollers rotate as the belt moves along.

[0061 ] Some of the support frames 6 in the system shown in Figure 1 and Figure 2 have height adjustment to assists with lifting the belt so that other idler rollers can more readily be replaced. The present invention is applicable to all of the idlers in such system, whether on height adjustable frames or fixed frames.

[0062] Figure 2 shows a close up of one of the support frames of figure 1 . The height adjustable frame 6 is shown, which is used to raise the belt clear of adjacent idler frames to assist in the replacement of idler rollers from those adjacent frames.

[0063] It will be appreciated that one or more embodiments of the present invention can be used with fixed or adjustable frames. Wherever a conveyor roller is used, an embodiment of the present invention can be used. Even if an embodiment of the present invention is present in a roller and fails, the roller can still continue to be used as a standard roller.

[0064] As shown in figure 3, a roller 10 (also termed an idler roller) for a conveyor system includes a cylindrical roller body 12 supported for rotation about a central axle 14 having an axis of rotation 16.

[0065] The external end of the axle includes a circumferential channel for mounting the roller to a notch in support frame (not shown) in a conventional manner. Such a channel is provided at each end of the axle. It will be appreciated that the axle does not need to rotate because bearings support the roller body for rotation on the axle.

[0066] A recess 20 extends into the end of the axle. A sensing module 22 is mounted within this recess. The module includes a battery, a transmitter and includes or is connected to at least one sensor, such as a vibration sensor, an accelerometer or a temperature sensor.

[0067] The transmitter can optionally transmit a unique code identifying the particular roller from other rollers. Alternatively or in addition, a physical unique code (such as a barcode) can be provided externally on the roller, such as on the end of the axle or exposed external surface of the module or potting material within which the module or components of the device may be protected. The module may include an RFID chip to transmit data relating to the module, the roller and/or sensed conditions.

[0068] The module can be a discrete unit that is inserted into the recess for use, and may be removed when the module fails or the battery needs replacing.

[0069] The apparatus may form part of a system including remote monitoring equipment which receives signals from the apparatus.

[0070] Maintenance of the roller can be conducted based on the data receive from the roller monitoring apparatus.

[0071 ] For example, if the bearings in the roller start to fail, the module will sense either an increase in vibration as the bearings become more worn, or an increase in temperature as the bearings start to heat up due to poor lubrication through wear, or a change in acceleration (such as wobble about the axle as the bearings wear and have more freeplay or rotational slipping as the bearings start to seize). [0072] In use, the roller condition monitoring device is preferably mounted in an end of the axle of the roller.

[0073] Alternatively, two devices can be mounted, one in each end of the axle, which may communicate sensed values with each other, or one of them to the other, or share data with other condition monitoring devices associated with or in adjacent rollers.

[0074] A roller condition monitoring device can be incorporated in or on a central region of the axle or in the roller body, between one end of the axle and the other end of the axle.

[0075] As a module, the device is received into the open end of the axle, and can be removed for maintenance and/or battery replacement.

[0076] The at least one sensor, such as a vibration sensor, an accelerometer or a temperature sensor, can be powered by the battery or by energy harvesting, such as through the minimal (normal) vibrations running through the roller from normal conveyor operation.

[0077] The device can optionally be interrogated by a remote device 26, to provide an update on sensed roller condition characteristics.

[0078] Alternatively, or in addition, the device can automatically provide an update of such characteristics and may provide an alert if a threshold is exceeded or unexpected condition identified.

[0079] For example, rapid temperature increase or rate of increase over a predetermined period of time, meeting or exceeding a temperature limit, meeting or exceeding a vibration limit or detecting a significant change in amount of vibration or vibration characteristics (such as a change in vibration frequency (Hz), periods during the day when vibration is better or worse (e.g. due to ambient weather, exposure/shade or conveyor operating conditions), or changes in acceleration (e.g. slipping or events of non-rotation or sudden slowing of rotation of the roller).

[0080] When transmitting or otherwise communicating the roller condition data, the device may also transmit or otherwise communicate the unique identifier for the roller. Thus, not only can the roller be rapidly changed (because the system recognised where in the conveyor that roller is positioned e.g. which roller frame), but the manufacture of the roller can be traced and any batches of faulty components identified and/or other rollers likely to fail can be identified before they fail.

[0081 ] Thus, the device, apparatus and/or system according to the present invention provides significant benefits in terms of early identification of roller failure and risk of premature conveyor damage or shutdown, as well as inventory and roller quality tracking and reporting.

[0082] The electronics within each conveyor roller may be powered by a battery 28. To save battery energy, the electronics can go into a sleep mode after a period of inactivity. For example, if the conveyor roller is in storage awaiting installation, such as in a warehouse facility, the electronics detect that no motion of the roller has occurred for a period of time, and the electronics go into a low power sleep mode. This saves battery power over time.

[0083] If the conveyor roller is awoken from sleep mode, such as by

movement of the roller or by interrogation from a communication device, the conveyor roller electronics may partially or fully 'power up'. Partial power up mode may include responding to a communication received by the conveyor roller for the conveyor roller to provide its unique reference identification and/or data relating to the size or type of roller. This is useful for audit purposes, such as stocktaking, whereby an assessment can be made of the number, type, size and location of the conveyor rollers within an inventory. [0084] Such assessments can be used for stock ordering purposes and for tracking ordering times for new stock, and thereby control or reduce lead times for need for replacement stock.

[0085] The conveyor roller, having received a communication or sensed its own movement, may be prompted or may automatically power up and commence sensing temperature, vibration and/or sound.

[0086] Sensed data and conveyor roller identification data may be provided wirelessly from a transmitter of the conveyor roller to a data gateway 24 serving multiple said conveyor rollers. The or each data gateway may output 27 the data to a client system 30 for monitoring and reporting purposes.

[0087] Sensed temperature or sound or vibration of the roller at or above a respective threshold for each sensed parameter may be provided as an alert to monitor the roller or replace the roller.

[0088] A first threshold for each parameter may be provided in order to generate a monitoring alert so that the conveyor roller can be scheduled for replacement or entered into a watch and monitor status.

[0089] A second threshold for each parameter may be provided that is higher than the first respective parameter such that elevated temperature, sound or vibration levels are alerted on a 'replace imminently', 'replace at next scheduled maintenance period' or 'replace now' basis.

[0090] For example, sound from the roller, such as rumbling bearings or damaged roller surface, sensed below 150db may indicate that the roller needs monitoring. Sensed sound above 150db can indicate a need to change the roller imminently. The level of sound for maintenance monitoring purposes may be, for example, between 120db and 150db. [0091 ] Time rate of change of sensed parameters can also be monitored. If the vibration, sound or temperature is/are increasing rapidly, an alert may be sent to the client system to indicate increasing failure rate of the roller and a need to replace the roller as soon as possible.

[0092] A data gateway within communication distance from a client system portal can provide data relating to multiple conveyor rollers for monitoring and reporting purposes. For example, to schedule failing rollers into the maintenance schedule. Thus, all rollers can communicate via a data gateway to a single monitoring point 26,30.

[0093] Data from the or each roller can be transmitted to a portable

processing device 26, such as a laptop computer, tablet or mobile

telecommunications device. For example, as a person or vehicle passes within range of the or each conveyor roller, data can be received by the respective portable device

[0094] One data gateway 24 may communicate data relating to the conveyor rollers within its range to another data gateway 24 serving other conveyor rollers. Thus, conveyor roller identification and/or sensed data may be 'daisy chained' from one data gateway to another in order to relay the data to the nearest output point, such as the nearest mobile device or other client system portal.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1 . A monitoring apparatus for a roller of a conveyor system, the apparatus including a roller monitoring device for mounting to the roller at or adjacent a central axis thereof.

2. A conveyor roller condition monitoring module for mounting to or in an end of an axle of the roller.

3. A conveyor roller condition monitoring apparatus, including a conveyor roller monitoring device providing a unique identifier to identify a conveyor roller to which the device is mounted or is incorporated.

4. A conveyor roller condition monitoring apparatus, including a conveyor roller monitoring device including at least one sensor including at least one of a vibration sensor, an accelerometer and a temperature sensor to sense a change in at least one of a respective sensed vibration, acceleration and temperature characteristic.

5. The conveyor roller condition monitoring apparatus of claim 3 including a transmitter to transmit a signal relating the unique identifier to a remote location.

6. The conveyor roller condition monitoring apparatus of claim 4 including a transmitter to transmit the respective at least one sensed vibration, acceleration and temperature characteristic to the remote location.

7. The conveyor roller condition monitoring apparatus of any one of the preceding claims including

8. A method for monitoring a plurality of conveyor rollers for an endless conveyor system, the method including the steps of: providing each said conveyor roller with an electronic conveyor roller monitoring device, and obtaining from one or more said rollers unique identification data identifying each said conveyor roller.

9. The method of claim 8, including obtaining from one or more of the conveyor rollers information providing an indication of one or more specification characteristics of the conveyor roller(s).

10. The method of claim 9, the specification characteristic(s) including size and/or type of conveyor roller for each said roller.

1 1 . The method of claim 10, whereby the information relating to the size of each said conveyor roller includes one or more of diameter, width or length specification.

12. The method of claim 10, whereby the information relating to the type of conveyor roller includes roller material.

13. The method of any one of claims 8 to 12, including conducting an audit by remotely communicating with each of the plurality of conveyor rollers and receiving from each of the conveyor rollers the unique identification data, and compiling the audit utilising the unique identification data.

14. The method of any one of claims 8 to 13, each of the conveyor rollers including at least one sensor, the method including, with at least one of the conveyor rollers mounted in use in the endless conveyor system, the at least one conveyor roller sensing that vibration, sound or temperature, or a combination of two or more thereof, at the respective at least one roller meets or exceeds a respective vibration, sound and/or temperature first threshold, and alerting a conveyor roller condition monitoring system of the vibration or temperature or sound or a combination of two or more thereof meeting or exceeding the respective first threshold(s).

15. The method of claim 14, including entering the said conveyor roller(s) into a maintenance schedule if the sensed temperature and/or vibration meets or exceeds the respective first threshold(s).

16. The method of claim 15, whereby the maintenance schedule includes conveyor roller condition monitoring reporting if the sensed temperature or vibration is at or above the respective first threshold(s) but below a higher respective vibration and/or temperature second threshold.

17. The method of claim 16, the monitoring of the roller condition between the first and second respective thresholds including monitoring for change in one or more of sensed temperature, sound or vibration.

18. The method of claim 16 or 17, whereby, when the second threshold is met or exceeded, a status indication is provided that the respective conveyor roller(s) need(s) prompt or urgent replacement.

19. The method of any one of claims 8 to 18, whereby each said conveyor roller includes electronics having a sleep mode whereby, after a period of non- use, the respective conveyor roller electronics enter a sleep mode to conserve battery power, and, when a communication is received by the electronics, the electronics come out of a sleep mode in order to communicate data.

20. The method of any one of claims 8 to 19, including each said conveyor roller providing data to a client system when awoken from a sleep mode or during use when interrogated by a remote communication device or system.

21 . The method of claim 20, whereby each said conveyor roller provides said data to a wireless gateway communicating with the client system.

22. A conveyor roller monitoring system including a plurality of conveyor rollers, each conveyor roller including electronics with at least one sensor for monitoring at least one condition or specification characteristic of the respective roller, and data output means to send data relating to the condition or

specification characteristic, each said conveyor roller sending said data to a respective data gateway communicating with a conveyor roller condition monitoring or reporting system.

23. The system of claim 22, wherein each said conveyor roller includes said at least one sensor for sensing one or more of vibration, sound or temperature.

24. The system of claim 22 or 23, the system integrated to communicate with a client data system.