WO2016161473A1

WO2016161473A1 - Conveyor pulley monitoring apparatus

Info

Publication number: WO2016161473A1
Application number: PCT/AU2016/000121
Authority: WO
Inventors: Antonio LUTZU; Wasyl DZIOMBAK; Mehrdad JAVADI; Nicholas Coplin; Vincent POTTIER; Tyron Utley; Donald Mark OKEBY
Original assignee: Orontide Group Ltd
Priority date: 2015-04-10
Filing date: 2016-04-08
Publication date: 2016-10-13
Also published as: AU2016245324A1; AU2016245324B2

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 MONITORING APPARATUS"

FIELD OF I VEN ION

[00 1 j The present invention relates to a conveyor pulley monitoring ap a tus.. In partieular_s the invention relates to a conveyor pulle monitorin apparatus integrated into a conveyor pulley locking device cover.

BACKGROUND

[000:21 Conveyor systems are used in manufacturing: and industry in a variet 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 set of conveyor pulleys and, iri use, is moved by one or more conveyor pulleys- that are powered {drive conveyor pulleys}:.

[0003] Each con veyor 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 throagh the pulley shell. Once the shaft has been centralized and positioned coxrecily, expandable locking device is used to fasten the pulley shell and 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 pulle end plate bores. The collar has a set of terssioned holts (being a bolt tightened t a specific torque) arranged about the collar's outer circuniference. 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 circumference, and causes the collar's inner ^■5 perimeter surface to constrict. This clamps tie pulle end plates to t e pulley shaft by a stron : interference lit and fastens the pulley shell to t e shaft.

[0006J After pulley shell has been fastened to its shaft, an additional protective cover may he fitted over the external pails of the locking device thai 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 transportatio of the conveyor pulley,

[00Q7] 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 is known for the tensioaed bolts of a locking device to crack or break as a result of corrosion or locking device igue caused by, for e ample, heav or irregular conveyor loads. Damaged tensioned belts significantly reduce the strength of lockin device and, by extension, the pulley- sheil o~shaft fastening,

[0008] It is,_: therefore, vital that tetssioned damaged bolts are identified and replaced by eo i ey r maintenance personnel as soon as possible, If the conveyor pulley assembl also has a protective cover installed over its locking device, it is wot uncommon fo tensioiied holt failures to g unnoticed for a substantial period of ti e, which can lead to catastrophic failure or serious damage to the conveyor pulle assembly,

[0009] Significant vibrational forces also act on conveyor systems during use, particularly in heavy industry and mining. Excessive vibrations can cause damage to conveyo system parts and unusual vibrations may be symptomatic of component failures that have occurred, including components not imnrediatel visible to, or accessible by, maintenanee personnel,

[0010] Other types of physical phenomena can als 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.. [0011 The present invention attempts to over come, at least: in pari, the aforementioned problems associated with conveyor systems.

SUMMARY OF THE INVEN IO

[0012] lit accoKian.ee 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 cover.

[0013] 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 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 an a second half, wherein the second half is substantially symmetrical to the first half The protective cover is made from a resilient non-metal!ie material and, preferably; a carbon or a composite carbon and Kevlar* based fil ment material ,

[0014] The integrated sensing means preferably comprises one or more sensin devices, wherein eac sensing device is capable of detecting and . measuring one or more physical phenomena, activities or conditions associated with a conveyor pulley, They 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.

[0013] 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 b unawthorked personnel. Preferabl 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 ta e. [0016] The protective cove preferably also comprises a wireless data transmission system fo wirelessly transmitting information collected using the. or each, sensing device to. a peripheral device, such as a handheld device operated by & servieeperson. Preferably, the transmission system uses Bluetooth*, a wireless: local area network (Wi- Fi) or other appropriate wireless communications technology,

[0017] in a preferred embodiment_* at least one sensing, device com prises a tensioned bolt sensor preferably disposed substantially opposite to a tensioned bolt of a locking devic installed on the convey r pulle and is capable of detecting a break, crack or other adverse issue associated with the pensioned boll. Preferably, the tensioned bolt sensor is affixed to the interior surface of the protective cover and comprises an electronic trigger that engages when a part of the tensioned. bolt breaks aao¾>r comes loose. Preferably, the eleetronie trigger engages when the part comes into contac 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,

[Q01 ] 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 (RPM).

[0020] in furthe preferred embodiment, at least one sensing device comprises a. pulley shaft deformation sensor capable of detecting and measurin 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 wit one or more strain gauges affixed to the pulley shaft.

[0021] In a further preferred embodiment, at least one sensing device comprise a pulley shell end plate deformation senso capable of detecting and measuring one or more efoliations to a pulley shell end plate. Preferably, the pulley shell end plate def rmation sensor operates in conjunction with one or more strain gauges affixed to the end plate.

[0022] 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.

[00:23] In a further preferred embodiment, at leas one sensing device comprises a sensor capable of detecting and measurin 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 device comprises a particle sensor capable of detecting and measuring parti cie cimianiination in a lubrication system of the conveyor pulley. Preferably, the particle sensor is capable of detecting and measuring particle contaminatio that comprises metal filings originating from one o more bearings, hearing housings and/or bearing accessories attached or near to a bearin 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.

[00251 hi a further preferred embodiment, the protective cover further comprises an identification means integrated with the protective cover. The identification means preferably comprises a radio- frequency identification; (RFID) tag connected to the protective cover, wherein the RFID tag has a unique identification (or "serial'-) number electronically encoded in the RFID tag that identifies the protective cover and the conveyor pulley. Preferably, the KPiD tag is embedded between the interior surface and the exterior surface of the protective cover and can be read whilst the eonveyor pulley is still running,

[0026] In a further preferred embodiment of the present invention, the protective cover preferably comprises an outer cover, an inne coyer and a sensor board. [0027] The sensor board may be disposed inside a first cavity of the protective cover, wherein the first cavity is fanned between- the outer cover and inner cover.

[0028 The protective cover may further 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 bolts of the locking device, fQ029] The second cavity may have a pair of opposed walls that are substantially apered, wherein the opposed walls are adapted to guide a tensioned bolt (or part thereof) that breaks and/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 eentre 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.. 0032] Alternatively, each sensing region of each sector may comprise one or more ultrasonic, optical, capacitive, magnetic, Hall-effect or other proximity or distance-based sensors,

[0033] Each control region of each sector may he adapted to communicate with one or more other control regions of others sectors of the sensor board and/or wit 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 comprisin the steps oil

integrating sensing means into a locking device protective cover;

installing the protective cover to a locking device of the conveyor pulley; and η using the sensing means to monitor the conveyor pulley when the conveyor^'' ulley is in operation.

BRIEF DESCRIPTION OF PRA i S

(0035] The present invention- will now be described, by wa of exam le_* with reference to the accompanying: drawings, in whieh_:;

[003.6] Figure 1(a) shows an isometric view of a conveyor pulle locking device as known in the art;

[003 ? j Figure 1 ( ) shows: a p artial side view of the locking devi ce of Figure 1 (a) ;

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

[0039] Figure 3 shows farther partial isometric view of the arrangement shown in Figure 2, wherein the locking device lias insialkd thereon a conveyor pulley monitoring apparatus according to a first embodiment of^* the preserrt 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 conveyor pulley monitoring apparatus according to a second embodimen of t e present invention:

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

[0043] Figure 7 shows a schematic representation of a sensor board that ma be used with the second embodiment shown in Figure 5 ; [00441 Figure S shows schematic diagram of electronic components oanipr sed m an electronic architecture utilised in the second embodiment shown in Figure 5;

[0045] Figure 9{a) shows a schematic diagram of electronic components comprised in an inductive metal sensor used in the second embodiment shown in Figure 5;

[0046] Figure 9( ) shows a schematic diagram of a plurality of inductive metal sensors arranged in a daisy- chain confi uration; and

[0047] Figure 10 is a schematic flow diagram showing execution steps of management .software embedded in a microcontroller- vt&ed i the second embodiment shown in Figure 5,

DETAILED DESCRIPTIO OF THE DRAWINGS

[0048] Referring to Figure 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 eollar 3 that has plurality of tensioned holts 5 disposed about an outer circumference 4 of the collar 3, Each tensioned holt 5 passes through the collar 3 transversely.

[0049] As shown in Figure !{¾ 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 1,3 and an upper outer wedge member 15.

[00S0] In use, when the bolt head 7 is tightened the tensioned bolt 5 is drawn into the collar 3 causing the inner wedge members 1 1 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 membe 13 in the direction indicated by reference numeral 19. Thi cause the outer circumference of the eollar 3 to expand force&lly and causes the circumference of the collar's 3 inner surface 20 to constrict. [00513 Referring to Figure 2_» there is shown a conveyor pulley 21 fastened to a pulley shaft 23 using the locking device 1. 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 pulle 21. . 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 fed through the bore 29 and through the hollow interior of the pulley shell 25,

[0053] After the shaft 23 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 2 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 ti htened 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 t constrict. This 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 conventional conveyor pulley 30 that has been fastened, to a pulley shaft 42 using a locking device 1.

[0055] The monitorin apparatus 31 comprises a conveyo pulley locking device protective cover 32. As most clearly shown in. Figure 4, the protective cover 32 preferably comprises a 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 L Once the protective cover 32 is in its -correct position, it is fastened to an end plate 50 of the conveyor pulley 30 y, for example, bolting the protective co er 32 to the end plate SO.

[0057] As best shewn in Figure 3, the protective cove 32 is substantially disc shaped. It will be appreciated, however, that alternative shapes are possible, for example, square, rectangular or polygon shapes, which are also within the scope of the present invention_*

[0058] Further, hi 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 1 has received certain upgrades during its service history.

[0059] In a further preferred embodiment, the protective cover 3 may comprise- a first half (not shown) and a second half (not shown) wherein the second half is substantially symmetrical and complementary to the first half. Having the protective cover 32 consisting of two complement ary halves allows the protective cover 32 to he partially dismantled and serviced, which may include retrofitting new parts, ithout completely removing the protective cover 32 from the conveyor pulley 30 that it is installed to.

[0060] According to 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 fo detectin and measuring various physical phenomena, conditions or activities tha may indicate actual, pending or potential structural or operational failnres 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 1 , which is a common point of failure for conveyor pulleys. As best shown, i Figure 3, the protective cover 32 will also commonly he situated in close proximity to a hearing 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 sensin means. [0062] Accordingly, the sensing wems in the present invention preferably comprises one or more sensing de ces 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 in the interior area .38 of the protective cover 33 <

[0063] The components comprising the, or eac , sensing devic are robust and capable of withstanding, substantial vibrations, shock and other physical conditions thai they may be subjected, to during use,

[0064] The, or each, sensing device may also comprise an- anti-tamper device that is capable of incapacitatin the sensing device or indicating when nnauthorized personnel attempt to open or access the components comprising the sensing device. For example, each anti-tamper device may comprise a volume of non-conductive liquid adhesive that adheres one or more vital components of the sensing device to wall of the sensing device's housing. Attemptin t 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 torn when a person attempts to open or access the com onents comprising the sensing device.

[G065 j The protective cover 32 preferabl 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 servieeperson. Preferably, the transmissio system uses Bluetooth⁹", a wireless local area netwerk (Wi-Fi) or other appropriate wireless communications technology.

[0066] In the exemplary embodiment shown in Figures 3 and 4, a plurality of sensing devices is shown wherein each sensing device comprises a tensioried 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 iensioned holt 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. [0 6S] Preferably, each- tensioned bolt sensor 44 is affixed to the interior surface 34 of the protective cover 32 and comprises aa electronic trigger 46 that engages when one or more tensioned holts 5 break and a part of the, or each, tensioned bol 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.

[0 69] Alternativel or additionally, the e!ectroriic trigger 46 also engages when the "free gap" between the head of the broken tension eel bolt 5 and the tensioned bolt sensor 4 is altered or disturbed, T¾s may happen, for example, when the tensioned bolt 5 has cracked o when fatigue alters the shape or geometry of the tensioned bolt 5 prior to actual final tare wherein the head of the tensione bolt 5 fully breaks away, 0070] Each tensioned bolt sensor 44 is capable of detecting multiple tensioned bolt 5 breakages. Bach sensor 44 is designed and manufactured usin resilient materials such that: any parts that break off from tensioned boft 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 exterio 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 tha each tensioned bolt sensor 44 will be capable of detecting tensioned bolt 5 breakages notwithstanding the barrier presented by th e interior surface 34,

[0072] In a i½rther 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 clam ed to.

[0073] It will be appreciated that the, or each, sensin device used in the present invention is not limited to 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 1:3 experienced % the conveyo pulley 30 and/or a conveyor system in which the conveyor pulley 30 is installed

[0074] 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 io RP .

[0075] in one farthe preferred embodiment, at least one sensing device comprises a deformation sensor (no shown} capable of detecting and measuring one o more deformations and/or deflections to the pulley shaft 42. The pulley shal deformation sensor preferabl 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 aftd measurin one or more deformations to an end plat 27 of the conveyor pulley 30. Preferably, th end plate deformation sensor operates in conjunction with one or more strain gauges (not shown) affixed to the end plate.

[0077] In on 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 con veyor pulle 3 is installed.

[0078] In one further preferred embodiment, at least one sensing device comprises a sensor (not shown) capable: of detecting and measuring excessiv lubricant present in region sensor {not sho wn) of the conveyor pulley 30 or a part of the conveyor system m which the eonveyor pulley 0 is installed,

[0079] In on further preferred embodiment, at least one sensing device comprises a particle sensor (not shown) capable of detecting and measuring particle- contamination in a lubrication -s stem- (not shown) of the conveyor pulley 30. The particl contamination m y be- capable of detecting and measuring many different forms of particle contamination which may include* for example, metal filings originating from one or more bearings, bearing housings and/or bearing accessories attadied or near to a bearing housing of the con veyor pulley (including, for example, a grease labyrinth)_*

[0080] 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 optimal position for detecting and measuring the relevant physical phenomena, conditions or activities that the relevant sensing device is intended to detect and measure. 0081 J_. it is not tiaeommon for conveyor pulleys to be used at multiple sites alter 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, in these situations, it is desirable for conveyor pulley manufacturers and users to be able to identif a conveyor pulley easily so that it can., for exampl , retrieve the conveyor pulley's service history, date of manufacture and deployment, or any operational data collected live' during operation of t he conveyor pulley on-site;, etc.

[0082] It 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 eanbodiment of the present invention the proteeti e cover 32, therefore, further comprises an identification means integrated with the protective cover 32.

[0084] As shown i Figure 4, the identification, means preferably comprises a radio- frequency identification (RFID) tag 52 affixed to the protective cover 32. Preferably, the RFID ta 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 cove 32 such that the RFID tag 32 is embedded etween the interior surface 34 and the exterior surface 36 of the protective cover 32. IS

[0086] The RFIP tag 52 has a unique identification (or 'serial') number electronically encoded within the RFID tag 52 that is associated with the protective cover 32 and, therefore by extension, associated with the conveyor pulley 30 that the protective eover 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 history and any other items of stored data relating to the conveyor pulley.

[00 ?1 It is possible that objects and materials ma come into contact with the protective cover 32 inadvertently during both installation and operation, For example, during operation materials being t nsported on the conveyor belt may Ml from the belt and hit e protective cover 32 or high pressure water ma be directed onto the cover during equipment cleaning. The protective cover 52 is, therefore, manufactured fr a tough, resilient material,

[0088] The protective cover 32 is preferably, manufactured from a mm- conductive material owing to the fact that conductive materials can adversely interfere with the electronics used in the, or each, sensing device or arty RF D tags 52 and wireless data transmission systems incorporated into the protective cover 32. These components could als corrode if not adequately protected and exposed over long periods to salt and moistures-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 articular;, in embodiments of th e present invention wherein the, or each, sensing device and any RFID tags 5.2 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 protect e co er 32 easily, thereby protecting these components, [00 1] 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 material han lin 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-iing materials disposed at and between* parts of the protective cover 32 where water and humidity ma penetrate suc as, tor 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 monitorin apparatus 3 i comprises a conveyor pulle locking device protective cover 5 that is installed over, and onto, a locking device 56 used to fasten conveyor pulley shell 25 to a pulley shaft 60.

£0093] The protective cover 54 comprises an outer cover 62 and an inne cover 64. The oute cover 62 and inner cover 64 are each, preferably, made from a tough,^■resilient iion-meiallie materia] such as a carbon or a composite carbon and evlar* based filament material.

[0094] The protective cover 54 farther 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. Th -sensor board 66 is disposed inside a first cavity 70 formed between the outer cover 62 and the inner cover 64.

[0095] The outer cover 62 serves to protect the locking device 56 and tensioned bolts 68 from the external environment. The inner cover 6 forms a barrier and serves to protect t e sensor board 66 from any tensioned bolts 68, or parts of tensioned bolts 68, that break off whi le the conveyor pulley 58 is in use.

[0096] As shown in Figure * the sensor board 66 may further comprise an additional protective layer 72 disposed on an exposed surface of the sensor board 66. The protective layer 72 serves to protect the sensor board 66 a«:d electronic components thereon from moisture.

[0:097] The protective cover 54 further comprises a bolt guide layer 74 which defines a second cavit 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.

[0098] 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 to guide the broken tensioned bolt 68, or parts thereof tow rds th direction of the sensor hoard 66 until they ©oroe into contact with, and are stopped by, the inner co er 64.

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

[001 0] As an alternative to using an inductive metal sensor, the sensor bo rd 66 may comprise an ltrasonic, optical, eapacitive, magnetic, Hail-effect or othe proximity or distai ee-based sensor.

[00101] Referring to Figure 7, there is shown, in schematic form, an exemplary representation of the sensor hoard 6 used in the embodifi eiit of th present in vention shown in Figures 5 and 6, The sensor board 66 comprises a plurality of sectors SO arranged in a daisy-chain configuration about a eommon centre to form a substautiaHy circular shape, The sensor board 66 is adapted such that it fits inside the .first cavity 70 of the protective cover 54.

[001 2] Each sector 80 eetsprises a sensing region 82 and a control region 84. Each sensing region 82 comprises sensing means used b the protective cover 54. Each control region 84 is adapted to receive and store data obtained by the respective sensing means.

[00103] Further, each o 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 is servieepersott, including by wireless communication to send and or receive data, obtained by the sensing means, on an intermittent or continuous signal basis.

[00104 j As an alternative to having multiple separate control regions $4, the protective cover 54 ma comprise a central microcontroller that communicates with, and controls, each o f the sensing regions 82,

[001 5] The outer cover 62, sensing board 66 and inner cover 64 are, preferably, each releasabl attachable from the protective cover 54 so as to facilitate ease of installation and maintenance of the protective cover 54.

[00106] As most clearly shown in Figure 6, the outer cover 62 m additionally comprise a groove in which may be di sposed an O-ring {no shown) made of rubber or similar material.. The Co in forms seal between the outer cover 62 and the pulley shaft 60 when the protective cover 54 is installed to prevent ingress of wate -and/or humidity durin operation,

[00107] F irtfeer, a lower section of the bolt guide layer 74 may also comprise groove 88 in which may be disposed an G-ring, made of rubber or similar material_* to form a seal between the bolt 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 io the normal O- ing shape seals as they are more perm nently affixed to the groove and therefore, the risk of nsssing iossng them during any maintenance or changeover will be reduced. Ensuring the seals remain in the grooves i important as the absence of seal 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/shaft (27 and 42/60) cart be further sealed with an additional layer of automoti ve style 'Sikaflex* silicone' or any other similar products. [00109] Referring to Figure there is shown a schematic drawing of electronic com onents comprised in an electronic architecture 90 utilised in the protective cover 54. The 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 microcoiitToIier 98.

[001 16] The system battery 92 is the principal power supply for the sensor board 66 of the protective cover 54. To facilitate installation and ease of removal, the system battery 9 is, preferably, housed inside a dedicated battery compartment (not shown) within the protective cover 54. It is preferred that the distance between the senso 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) misreadin the batter (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 suc as a USB port for connecting to the microcontroller,

[001 1 Γ] The system battery 92 supplies electrical power to the battery management unit 94 via a single power rail 100. The battery management unit 94, in turn, produces and supplies appropriate voltage aiid electrical currents to all other components of the protective cover 54 that .re uire electrical power, i cludin 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 communication power line 108.

[001 12] To m aximise the life of the system ^'battery- 92, the battery management unit 94 operates, in conjunction with the microcontroller 98 via a inicrocoiitroller control line 1 10, 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. 2ί)

[001 13] The microcontroller 98, preferably, comprises embedded code that im lements real time calendar for activating and ._.deactivating the power supply and. powered components of the protective cover 34 according to pre-determined wake up and maintenance intervals.

[00114] The battery management unit 94, in conjunction with the microcontroller 98 and a coimaiaiicatioais control line 1 1 , additionally reports the battery charge and stains to one or more peripheral devices via the communication means 1.0,6* which may c mprise a wireless eommuni cation means, enabling maintenance and services personal to monitor the battery, The microcontroller 9$ may also access pre-determined battery life schedule from a remote network location via the communication, .mea«s- 106, which the microcontroller 98 uses to raise alert notifications when the system battery 92 needs to be replaced prior to a predicted, powe failure.

[0 )1 15] Referrin to Fi u e 9{a)._; there is shown 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 1 16 comprises spiralled coil detectio antenna 118 formed,_, preferably, using copper ^' track on the sensor board 66, The antenna 1 18 is positioned and aligned in the sensor board 66 such that it ma accurately detect when a particular tensioned bolt 68, or parts thereof, have broken off and moved towards the direction of th inductive metal sensor 1 16.

[00116] The inductive metal sensor 1 16 further comprises a driver circuit 120 and driver circuit gate 122 which communicate with the microcontroller 8 a d or adj cent inductive metal sensors when, as shown in Figure 9{b)_s a. plurality of sensors are arra ged on the sensor board 66 in a dais -chain confi uration,

[001 17] The microcontroller 98 has management software embedded therein for driving the components of the architecture 90,

[001 18] The management software include a calibration routine which establishes existin tensioned bolt 68 p sitions and the breakage thresholds required to ena le each sensor driver circuit 120 to accuratel detect tensioned bolt breakages during subsequent use. The calibration routine, preferably, establishe the necessary thresholds and tolerances rasing a learning algorithm, in conjunction with empirical data, aid, once caleulated, stores the values to non-voiatile 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-assernbied for system maintenance purposes_*

[00120] Referring to Figure 10, there is provided a schematic flow di gram showing procedural steps 124 that are executed by the management software, onee calibration has been performed and completed,

[00121 ] As disclosed above, to preserve the life of the S stem battery 92 and maximise time interval between charges, the microcontroller 98 and battery management unit 9.4, together, ensure that power is only supplied to the powered components of the protective cover S _j includin 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, for most of the time, left in a powered -down idle state,

[00122] When the management software determines, according to its predetermined- schedule, that the protectiv cover 54 is required to wake up and enter an active state, the software executes a system initialisati n procedure 126 before executin 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 bolt breakages have occurred.

[001243 The software then executes a courmunications procedure 132 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, mobile telephone, tablet or laptop, A peripheral device ma also comprise, b way of further example, a relay station that relays the information to a central controller for display via a Supervisory Control And Data Acquisition (SCAD A) system.

[00125] The software then executes a- system power down procedure 134 before reentering its power saving mode 13:6_* A scheduling alarm routine 138 executed by fee management software keeps the system in an idle state before the next set of active readings need to be take according to the^■■ re-determined schedule,

[00126] The pre-deienniiled schedule may he stored in non-volatile memory in the mieroeontroller 98.

[00127] In the event that bolt breakage is detected during the evaluation procedure 130, the manageineni software records this, along with a timesiarnp, to non-volatile memo within the mierocontrol!er 98 so that the status is latched and ma not be reset unless and until the relevant tensioned bolt 68 has been replaced and a buman operate has reset the rson-volaiile me ry_*

[001 8] The software may be configured so that it detects, records and repo ts 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 o f tensioned bolts 68 have failed.

[00129] Modifications and variations as would be apparent to a skilled addressee are deemed to he 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 monitorin apparatus eomprismg sensing means that:

are capable of detecting and measuring one or more physical phenomena, activities or conditions associated with the conveyor pulley; and

are integrated into a protective cover of the locking device,

2. A monitoring apparatus according to claim 1 , wherein the protective cover comprises an exterior surface and an interior surface, the interior surface defining an internal area of the protective cover.

3. A monitoring apparatus accordin to claim 2, wherein the sensing means are disposed in the internal area.

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

5> A monitoring apparatus according to any one of the preceding claims, wherein the sensing means comprises at least one bolt detector, the or each bolt detector being adapted to detect a break, crack, movement or adverse issue associated with a tensi oned bolt of the locking device.

6. A monitoring apparatus according to claim 5, wherein the, or each, bolt detecto is disposed substantially opposite to a teixsione bolt of the locking device.

7. A monitoring apparatus according to Claim 5 o 6, wherein the, or each, bolt detector comprises an electroni c 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.

8.. A rao torin apparatus according to claim 5 or 6_; wherein the, or each, bolt detector comprises an electronic trigger that engages when a shape or geometry of a ^•teflsiotied boil of the locking device changes tine to cracking or fatigue during use o the conve or pulley,

9. A monitoring apparatus according to any preceding dai! , wherem the apparatus comprises a identification means for identifying the conveyor pulley or a part thereof,

1(1. A monitorin apparatus according to claim 9. wherein the identification means comprises radio-frequency^■.identification tag (RPID),

11, A Oiritorifig apparatus according to claim 1 , wherein the protective cover comprises an outer « -w, an inner cover and a sensor hoard, 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; and

the inne co ver protect s the sensor board from a tensloned holt of the locking device, or pari thereof, that breaks when the conveyor pulley is in use.

12. A monitoring apparatus according to claim 11 , wherein the protective cover comprises a bolt guide layer that defines a second cavity enclosing, at ieast in part, one or more tensioned bolts of the lockin device.

13 , A monitoring apparatus aceordin to claim 1 , 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,

14. A monitoring apparatus accordin to any precedin claim, wherein the sensing means comprises at least one inductive metal sensor.

15, A monitoring apparatus according to any preceding claim, wherein the protecti ve cover comprises a groo ve haying an O-ring disposed therein, wherein the O-ring forms a seal between the protective cover and the pulley shaft

16. A monitoring apparatus according to any preceding claim, wherein the protective cover c mprises a groove having an O-ring disposed therein, wherein the O-ring forms a seal between the protective cover and an end plate of a pulley shell of the conveyor ulley.

17. A monitoring apparatus according to any preceding claim, -wherein the apparatus comprises a wireless data trans ssiOn system for wirelessly transmitting data collected using the sensing means to a peripheral device.

18. A Q Mtstormg apparatus according to claim 17, wherein the wireless data transmission system uses Bluetooth'* technology.

1 . A monitoring apparatus according to any preceding claim, wherein the sensing means comprises at least one vibration sensor_*

2.0. A protective cove t¾r a locking device, the locking device being -adapted to fasten a conveyor pulley to a pulley sliaft, wherein the protective cover comprises sensing means that:

are capable of detecting and measuring one or more physical phenomena, acti vities or conditions associated with the conveyor pulley; and

are integrated into the protective cover.