WO2018032040A1 - A belt rip detection system - Google Patents

A belt rip detection system Download PDF

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Publication number
WO2018032040A1
WO2018032040A1 PCT/AU2017/050838 AU2017050838W WO2018032040A1 WO 2018032040 A1 WO2018032040 A1 WO 2018032040A1 AU 2017050838 W AU2017050838 W AU 2017050838W WO 2018032040 A1 WO2018032040 A1 WO 2018032040A1
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WO
WIPO (PCT)
Prior art keywords
conveyor belt
belt
rip
profile
sensor
Prior art date
Application number
PCT/AU2017/050838
Other languages
French (fr)
Inventor
Ankit ASARPOTA
Brett Davies
Tim GALVIN
Andre GRACE
Mick GREEN
Shane NEW
Greg PIENAAR
Edward SURYAWINATA
Satyajith SUVARNA
Michael Thomas
Jamie White
Original Assignee
Technological Resources Pty. Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2016903274A external-priority patent/AU2016903274A0/en
Application filed by Technological Resources Pty. Limited filed Critical Technological Resources Pty. Limited
Priority to AU2017313433A priority Critical patent/AU2017313433B2/en
Priority to CA3034180A priority patent/CA3034180C/en
Publication of WO2018032040A1 publication Critical patent/WO2018032040A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating

Definitions

  • the present invention relates to a belt rip detection system for detecting a rip in a belt of a conveyor, and in particular for detecting a rip in a belt of a conveyor of the type used to transport material in a mining operation.
  • a belt rip detection system for a conveyor including a conveyor belt comprising: a belt separator including at least two idler rollers, the belt separator arranged to support the conveyor belt on the at least two idler rollers, and to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator; and
  • the belt separator includes first and second oppositely disposed inclined rollers arranged to support the conveyor belt, with no support for the conveyor belt between the first and second inclined rollers.
  • the angle of inclination of the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable.
  • a spacing distance between the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable.
  • the system includes a plurality of sensors, each sensor arranged to produce conveyor belt profile information for a substantially different portion of the conveyor belt, and the system arranged to use the profile information from any one or more of the sensors to determine whether a rip is present in the conveyor belt.
  • the at least one sensor includes at least one laser scanner arranged to scan across at least a section of the conveyor belt and produce distance information indicative of a profile of the conveyor belt section as the laser scans across the conveyor belt section.
  • the laser scanner may include a plurality of laser sensors, each laser sensor arranged to scan across a substantially different portion of the conveyor belt section and produce distance information indicative of a profile of the conveyor belt portion as the laser scans across the conveyor belt portion.
  • the at least one sensor includes a plurality of direct line of sight sensors, each direct line of sight sensor arranged to provide a signal indicative of the distance to the conveyor belt along a different direct line of sight, wherein the lines of sight of the sensors are substantially parallel. The lines of sight may extend generally horizontally.
  • the at least one sensor includes at least one ultrasonic sensor.
  • a plurality of ultrasonic sensors may be provided, each ultrasonic sensor arranged to cover a substantially different portion of the conveyor belt and produce distance information indicative of a profile of the conveyor belt portion.
  • the at least one sensor includes at least one radar sensor. In an embodiment, the at least one sensor includes at least one inductive sensor.
  • the system includes a display arranged to visually display the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt.
  • the system is arranged to automatically compare the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt with reference conveyor belt profile information and to generate an alert signal when the comparison indicates that a rip is present in the conveyor belt.
  • the alert signal may be communicated to a control system of the conveyor belt.
  • the reference information may be comprise a load factor signal representing expected deviation of the conveyor belt in response to an applied load when the conveyor belt is not ripped, the load factor signal derived using a mathematical model of a loaded belt.
  • the reference information may be comprise a lookup table of reference sensor values for a loaded belt.
  • a method of detecting a rip in a conveyor belt of a conveyor comprising: providing a belt separator including at least two idler rollers;
  • the belt separator arranged to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator;
  • Figure 1 is a schematic block diagram of components of a belt rip detection system in accordance with an embodiment of the present invention
  • Figure 2 is a diagrammatic representation of a belt separator of the belt rip detection system, components of which are shown in Figure 1 ;
  • Figure 3 is a plot of a profile of a portion of a conveyor belt wherein the belt portion does not have a rip, the plot obtained using a laser scanner
  • Figure 4 is a plot of a profile of a portion of a conveyor belt wherein the belt portion includes a rip, the plot obtained using a laser scanner
  • Figure 5 shows plots indicative of a profile of a portion of a conveyor belt wherein the belt portion includes a rip, each plot corresponding to a respective channel of a laser scanner and each plot corresponding to a different view direction of the laser scanner;
  • Figure 6 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, the plots obtained using ultrasonic sensors
  • Figure 7 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, the plots obtained using ultrasonic sensors and over a longer time period than the plots shown in Figure 6;
  • Figure 8 is a diagrammatic representation of a conveyor belt and set of ultrasonic and radar sensors of a belt rip detection system in accordance with an embodiment of the present invention when no rip is present in the belt;
  • Figure 9 is a diagrammatic representation of components of a belt rip detection system similar to the system shown in Figure 8 when a central rip is present in the belt;
  • Figure 10 is a diagrammatic representation of components of the belt rip detection system shown in Figure 9 when a skirt rip is present in the belt;
  • Figure 1 1 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, each plot corresponding to a respective ultrasonic sensor of the system shown in Figure 8 and each plot corresponding to a different view direction;
  • Figure 12 shows the plots of Figure 1 1 after filtering and application of rip detection logic;
  • Figure 13 is a diagrammatic representation of components of a belt rip detection system in accordance with an alternative embodiment of the present invention when no rip is present in the belt, the system using alternative scanners to produce information indicative of the change in profile of the belt;
  • Figure 14 is a diagrammatic representation of components of the belt rip detection system shown in Figure 13 when a central rip is present in the belt;
  • Figure 15 is a diagrammatic representation of components of the belt rip detection system shown in Figure 13 when a skirt rip is present in the belt. Description of an Embodiment of the Invention
  • FIG. 1 and 2 of the drawings there is shown a belt rip detection system for detecting a rip in a conveyor belt 12 of a conveyor, in particular a conveyor used in the resources industry.
  • the system includes operative components 10 shown in Figure 1 and a belt separator 14 shown in Figure 2.
  • the system operates such that the belt separator 14 supports a conveyor belt 12 and induces a change in profile of the conveyor belt 12 adjacent a rip when a rip is present in the conveyor belt 12, and one or more sensors are used detect the change in profile of the conveyor belt 12 and thereby presence of the rip in the conveyor belt 12.
  • the belt separator 14 shown in Figure 2 includes a frame 16, in this example having a base portion 18, end portions 19, and first and second roller mount portions 20, 22 arranged to rotatably support respective first and second idler rollers 24, 26.
  • the first and second idler rollers 24, 26 are connected to the base portion 18 at one of several pivot connections 23 and to a respective end portion 19 at one of several roller mount connections 25 through a support rod 29, the length of which between the end portion 19 and the roller mount portion 20, 22 is adjustable.
  • the separation distance between the first and second idler rollers 24, 26 and the angle of inclination of the idler rollers 24, 26 is adjustable, for example by adjusting the location of the pivot connection 23 of the roller mount portions 20, 22, adjusting the location of the roller mount connection 25 to which the support rod 29 is connected, and/or adjusting the length of the support rod 29.
  • Modifying the idler roller separation distance and/or the angle of inclination of the idler rollers 24, 26 enables the support locations of the conveyor belt 12 indicated by arrows 27 to be modified, and it will be understood that facilitating modification of the support locations 27 enables the profile change of the conveyor belt 12 in response to a belt rip to be made more detectible, particularly for rips that occur at skirt portions of the conveyor belt 12. It will also be understood that increasing the angle of inclination of the idler rollers 24, 26 has a squeezing effect on the conveyor belt 12.
  • the inventors have established that supporting the conveyor belt 12 towards longitudinal edges of the conveyor belt 12 increases the likelihood that a detectible profile change will occur in response to a rip in the conveyor belt 12 because profile changes are more likely to occur between the support points and less likely to occur outwardly of the support points. Accordingly, a rip occurring between the support points is more likely to be detectable than a rip outside of the support points. Also, the inventors have established that the squeezing effect caused by increasing the angle of inclination of the idler rollers 24, 26 also increases the likelihood that a detectible profile change will occur in response to a rip in the conveyor belt.
  • the belt separator 14 includes a void region 28 between the first and second idler rollers 24, 26.
  • a central idler roller would be provided that is rotatable about a generally horizontal axis, the central idler roller providing a degree of support for a belt in addition to the support provided by 2 side idler rollers.
  • the inventors have established that the presence of a central idler roller reduces the amount of profile change that occurs in a belt when the belt is ripped and as a consequence a rip is more difficult to detect. Without the central idler roller, belt sag in response to a rip is more pronounced and therefore more likely to be detectible as a profile change.
  • the operative components 10 shown in Figure 1 include at least one sensor 30 that is configured to produce information indicative of a profile of the belt, which can then be used to determine whether a change of significance has occurred to the belt profile and thereby whether a rip is present in the belt.
  • a sensor assembly including several sensors, for example 8 sensors, is provided.
  • the sensors may be any suitable sensors capable of producing information indicative of the profile of the belt, for example laser sensors, ultrasonic sensors, inductive sensors and/or radar sensors.
  • each sensor is arranged to detect distance to a conveyor belt in a field of view of the sensor without touching the conveyor belt, although it will be understood that alternatives are envisaged.
  • the operative components 10 also include a control unit 32 arranged to control and coordinate operations in the system and in particular implement an analysis engine 34 arranged to use signals produced by the sensors 30 to produce profile information that can be used by an operator to determine whether a rip is likely to be present.
  • the analysis engine 34 is arranged to automatically compare the detected profile with a reference profile for the conveyor belt 12 and to generate an alert signal when the detected profile exceeds a defined threshold compared to the default profile.
  • the alert signal in this example is communicated directly to a conveyor belt control system, such as a PLC of the conveyor belt control system.
  • the analysis engine 34 may also be arranged to determine when a sensor is operating incorrectly, for example because the sensor blocked, and to trigger an alert to indicate that the sensor requires cleaning.
  • the analysis engine 34 may also be arranged to produce information indicative of a visual representation of the belt profile for display to the operator, for example one or more plots indicative of the profile of the conveyor belt 12.
  • the operative components 10 may also include a display 40 for displaying information to an operator indicative of the determined belt profile.
  • control unit includes a processor 35 and the operative components 10 also include a data storage device 36 arranged to store programs and data used by the processor 35 to implement the desired functionality, and a memory 36 used by the processor to temporarily store programs and/or data during use.
  • the operative components 10 may include an alert unit 42 arranged to produce an alert, for example a visible or audible alert to an operator, when the analysis engine 34 generates an alert signal to indicate that the detected profile exceeds a defined threshold compared to a reference profile.
  • an alert unit 42 arranged to produce an alert, for example a visible or audible alert to an operator, when the analysis engine 34 generates an alert signal to indicate that the detected profile exceeds a defined threshold compared to a reference profile.
  • a plot 44 is shown that illustrates distance measurements obtained from a laser scanner that has a conveyor belt in a field of view of the laser scanner. Since the laser scanner measures distance from the laser scanner to an object across a field of view of the laser scanner, the plot 44 is therefore representative of the profile of the belt. As shown, while some noise is present, a general belt profile represented by broken line 45 can be seen.
  • a plot 46 is shown that illustrates distance measurements obtained from the laser scanner that has a ripped conveyor belt in the field of view of the laser scanner.
  • the plot 46 includes a first profile portion 47 that corresponds to an upper portion of a side of the belt, and second profile portion 48 that corresponds to a lower portion of the belt.
  • a discontinuity 50 is present between the first and second profile portions, and that the second profile portion 48 sags relative to the first profile portion 47. This indicates that a rip is present in the conveyor belt 12 between the first and second profile portions.
  • a general ripped belt profile without noise is represented by broken line 51 .
  • the senor(s) 30 may take the form of one or more laser scanners or direct line sensors of the type arranged to provide distance data in separate channels.
  • 8 data plots 52, 54, 56, 58, 60, 62, 64 as shown in Figure 5 are produced by a plurality of laser scanners. Each plot corresponds to a different direction of view of a laser scanner and therefore each plot corresponds to a different portion of the section of belt that faces the laser scanners. In this example, therefore, a first plot 52 corresponds to an upper portion of a side of the belt and an eighth plot 64 corresponds to a lower portion of the side of the belt adjacent a central portion of the belt.
  • plots 66, 68 are shown that illustrate distance measurements obtained from an ultrasonic distance measuring device.
  • a first plot 66 corresponds to a first ultrasonic sensor of the device and a second plot 68 corresponds to a second ultrasonic sensor of the device.
  • the ultrasonic device measures distance from the device to an object in the field of view of the device, and the plots 66, 68 are therefore representative of the profile of the belt at 2 locations.
  • the first plot 66 corresponds to a lower portion of a side of the belt and the second plot 68 corresponds to an upper portion of the same side of the belt.
  • a discontinuity 69 exists that represents a skirt rip.
  • a center rip 67 is also detected.
  • the second plot 68 does not detect the skirt rip because it is placed too high relative to the belt. In this way, the second ultrasonic sensor serves to provide a default plot of the belt that is less likely to respond to rips in the belt.
  • Figure 7 shows first and second plots 70, 72 for the respective first and second ultrasonic sensors over a longer time period than the plots 66, 68 shown in Figure 6.
  • each ultrasonic sensor has a sensor field of view 80 corresponding to an approximate 200mm spot size directed upwardly towards the conveyor belt 12 and covering a different part of the conveyor belt 12, and each ultrasonic sensor 74 is arranged to provide a signal indicative of the minimum distance to an object in the field of view. It will however be understood that sensors with other spot sizes are envisaged.
  • Figure 9 shows the position of the conveyor belt 12 relative to the field of view 80 of a set of 8 ultrasonic sensors when a center rip 82 is present in the belt. Like and similar features are indicated with like reference numerals.
  • a rip 82 in the centre of the conveyor belt 12 causes a central portion of the belt to sag, and as a consequence the distance measurements produced by the 4 th and 5 th sensors will detectably reduce. There may also be a small change in the distance measurements produced by the 3 rd and 6 th sensors, but most likely no identifiable change in the distance measurements produced by the 1 st and 8 th sensors.
  • Figure 10 shows the position of the conveyor belt 12 relative to the field of view 80 of the sensors when a skirt rip 84 is present in the belt.
  • a rip 82 in a skirt portion of the conveyor belt 12 causes minor sagging adjacent the skirt rip 84, and as a consequence the distance measurements produced by the 6 th and 7 th sensors will detectably reduce.
  • Figure 1 1 shows plots 85 derived from the ultrasonic sensors 74 shown in Figure 8, the plots 85 corresponding to raw signals indicative of distance to the conveyor belt from each of the sensors 74. As each sensor 74 corresponds to a different field of view, the raw signal derived from each sensor 74 is indicative of whether a rip is present at a portion of the conveyor belt 12 in the field of view 80 of the sensor.
  • Figure 1 1 also includes a plot 86 of conveyor belt load.
  • the profile of a belt with no rips changes significantly with changes in load, and accordingly in order to determine changes in belt profile in response to presence of a rip, it is necessary to generate reference data indicative of a loaded belt with no rips and to compare the measured profile data with the reference data in order to determine whether a rip is present.
  • the reference data may be derived in any suitable way, for example using a mathematical model of a loaded belt or using a lookup table of reference sensor values for a loaded belt.
  • Figure 12 shows plots 88 that correspond to the ultrasonic sensor-derived plots 85 of Figure 1 1 after filtering, a plot 90 indicative of a load factor representing expected vertical deviation of the conveyor belt in response to an applied load represented by the load plot 86, and a plot 92 that includes pulses 94 indicative of detected rips in the conveyor belt 12.
  • filtered signals represented by plots 88 are produced.
  • a rip on the conveyor belt 12 can be detected, and pulses 94 generated corresponding to the location(s) of the rip(s).
  • a generated pulse 94 is provided to a PLC of a conveyor belt control system.
  • the following methodology is used.
  • steady state sensor signals are produced that represent the profile of the conveyor belt when the conveyor belt is not loaded and when no rips are present in the belt.
  • signals indicative of the loaded profile of the conveyor belt are obtained from the ultrasonic sensors.
  • a transverse belt load factor based on a belt sag model is determined empirically from test data, and an error signal is determined by comparing the measured loaded profile signals with the expected loaded profile determined using the determined belt load factor.
  • a moving average for example of 10 successive determined values in the error signal, is then determined, and if there is a deviation greater than a defined threshold, for example a reduction in distance to the belt of 8mm or greater, a pulse 94 is added to the detected rip plot 92 to indicate that a rip is considered to be present in the conveyor belt 12.
  • a defined threshold for example a reduction in distance to the belt of 8mm or greater
  • each laser sensor assembly 100 includes 1 1 laser sensors.
  • Each laser sensor is arranged to provide a signal indicative of the minimum distance to an object in the field of view located along a direct line of sight 102 extending generally horizontally from the sensor, and the sensors are configured so that the lines of sight 102 of the sensors are parallel.
  • Figure 13 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when no rip is present in the conveyor belt 12. As shown, the lowermost sensor is disposed such that the line of sight passes slightly under the central portion of the conveyor belt 12.
  • Figure 14 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when a center rip 104 is present in the belt.
  • a rip 104 in the centre of the conveyor belt 12 causes a central portion of the belt to sag, and as a consequence the distance measurements produced by the first 4 sensors will detectably reduce. There will most likely be no identifiable change in the distance measurements produced by the 5 th to 8 th sensors.
  • Figure 15 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when a skirt rip 106 is present in the belt.
  • a rip 106 in a skirt portion of the conveyor belt 12 causes minor sagging adjacent the skirt rip 106, and as a consequence the distance measurements produced by the 7 th and 8 th sensors will detectably reduce. There is likely to be no identifiable change in the distance measurements produced by the 1 st to 6 th and 9 th to 1 1 th sensors.

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  • Control Of Conveyors (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

A belt rip detection system for a conveyor including a conveyor belt is disclosed. The system has a belt separator including at least two idler rollers, and the belt separator is arranged to support the conveyor belt on the at least two idler rollers, and to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator. The system also includes at least one sensor arranged to produce information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt and thereby presence of the rip in the conveyor belt.

Description

A BELT RIP DETECTION SYSTEM
Field of the Invention The present invention relates to a belt rip detection system for detecting a rip in a belt of a conveyor, and in particular for detecting a rip in a belt of a conveyor of the type used to transport material in a mining operation.
Background of the Invention
It is known to use conveyors in the resources industry to transport material between different stages and/or different components of a production workflow. For example in an iron ore production facility, it is typical to use conveyors to transport ore to/from crushing equipment, transportation trains, and equipment at a port facility. Such conveyors are critical to the production process and as a consequence any downtime of a conveyor can have a significant effect on production and therefore cost.
A belt rip that is less than the full length of the conveyor, for example up to 150m, can be temporarily repaired with mechanical fasteners, with a proper repair typically done in the next scheduled shutdown. Full length belt rips, however, require immediate replacement and therefore immediate shutdown of the conveyor, which is expensive in terms of both loss of production and materials cost for a new conveyor belt.
It is therefore desirable to avoid occurrence of full length rips and the associated effect on production downtime and cost.
Summary of the Invention
In accordance with a first aspect of the present invention, there is provided a belt rip detection system for a conveyor including a conveyor belt, the system comprising: a belt separator including at least two idler rollers, the belt separator arranged to support the conveyor belt on the at least two idler rollers, and to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator; and
at least one sensor arranged to produce information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt and thereby presence of the rip in the conveyor belt. In an embodiment, the belt separator includes first and second oppositely disposed inclined rollers arranged to support the conveyor belt, with no support for the conveyor belt between the first and second inclined rollers.
In an embodiment, the angle of inclination of the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable.
In an embodiment, a spacing distance between the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable.
In an embodiment, the system includes a plurality of sensors, each sensor arranged to produce conveyor belt profile information for a substantially different portion of the conveyor belt, and the system arranged to use the profile information from any one or more of the sensors to determine whether a rip is present in the conveyor belt.
In an embodiment, the at least one sensor includes at least one laser scanner arranged to scan across at least a section of the conveyor belt and produce distance information indicative of a profile of the conveyor belt section as the laser scans across the conveyor belt section. The laser scanner may include a plurality of laser sensors, each laser sensor arranged to scan across a substantially different portion of the conveyor belt section and produce distance information indicative of a profile of the conveyor belt portion as the laser scans across the conveyor belt portion. In an embodiment, the at least one sensor includes a plurality of direct line of sight sensors, each direct line of sight sensor arranged to provide a signal indicative of the distance to the conveyor belt along a different direct line of sight, wherein the lines of sight of the sensors are substantially parallel. The lines of sight may extend generally horizontally.
In an embodiment, the at least one sensor includes at least one ultrasonic sensor. A plurality of ultrasonic sensors may be provided, each ultrasonic sensor arranged to cover a substantially different portion of the conveyor belt and produce distance information indicative of a profile of the conveyor belt portion.
In an embodiment, the at least one sensor includes at least one radar sensor. In an embodiment, the at least one sensor includes at least one inductive sensor.
In an embodiment, the system includes a display arranged to visually display the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt.
In an embodiment, the system is arranged to automatically compare the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt with reference conveyor belt profile information and to generate an alert signal when the comparison indicates that a rip is present in the conveyor belt. The alert signal may be communicated to a control system of the conveyor belt.
In an embodiment, the reference information may be comprise a load factor signal representing expected deviation of the conveyor belt in response to an applied load when the conveyor belt is not ripped, the load factor signal derived using a mathematical model of a loaded belt.
In an embodiment, the reference information may be comprise a lookup table of reference sensor values for a loaded belt.
In accordance with a second aspect of the present invention, there is provided a method of detecting a rip in a conveyor belt of a conveyor, the method comprising: providing a belt separator including at least two idler rollers;
supporting the conveyor belt on the at least two idler rollers, the belt separator arranged to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator; and
using at least one sensor to obtain profile information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt and thereby presence of the rip in the conveyor belt.
Brief Description of the Drawings
The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic block diagram of components of a belt rip detection system in accordance with an embodiment of the present invention;
Figure 2 is a diagrammatic representation of a belt separator of the belt rip detection system, components of which are shown in Figure 1 ;
Figure 3 is a plot of a profile of a portion of a conveyor belt wherein the belt portion does not have a rip, the plot obtained using a laser scanner; Figure 4 is a plot of a profile of a portion of a conveyor belt wherein the belt portion includes a rip, the plot obtained using a laser scanner;
Figure 5 shows plots indicative of a profile of a portion of a conveyor belt wherein the belt portion includes a rip, each plot corresponding to a respective channel of a laser scanner and each plot corresponding to a different view direction of the laser scanner;
Figure 6 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, the plots obtained using ultrasonic sensors; Figure 7 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, the plots obtained using ultrasonic sensors and over a longer time period than the plots shown in Figure 6;
Figure 8 is a diagrammatic representation of a conveyor belt and set of ultrasonic and radar sensors of a belt rip detection system in accordance with an embodiment of the present invention when no rip is present in the belt;
Figure 9 is a diagrammatic representation of components of a belt rip detection system similar to the system shown in Figure 8 when a central rip is present in the belt;
Figure 10 is a diagrammatic representation of components of the belt rip detection system shown in Figure 9 when a skirt rip is present in the belt;
Figure 1 1 shows plots indicative of a profile of a portion of a conveyor belt where the belt portion includes a rip, each plot corresponding to a respective ultrasonic sensor of the system shown in Figure 8 and each plot corresponding to a different view direction; Figure 12 shows the plots of Figure 1 1 after filtering and application of rip detection logic;
Figure 13 is a diagrammatic representation of components of a belt rip detection system in accordance with an alternative embodiment of the present invention when no rip is present in the belt, the system using alternative scanners to produce information indicative of the change in profile of the belt;
Figure 14 is a diagrammatic representation of components of the belt rip detection system shown in Figure 13 when a central rip is present in the belt; and
Figure 15 is a diagrammatic representation of components of the belt rip detection system shown in Figure 13 when a skirt rip is present in the belt. Description of an Embodiment of the Invention
Referring to Figures 1 and 2 of the drawings, there is shown a belt rip detection system for detecting a rip in a conveyor belt 12 of a conveyor, in particular a conveyor used in the resources industry.
The system includes operative components 10 shown in Figure 1 and a belt separator 14 shown in Figure 2.
The system operates such that the belt separator 14 supports a conveyor belt 12 and induces a change in profile of the conveyor belt 12 adjacent a rip when a rip is present in the conveyor belt 12, and one or more sensors are used detect the change in profile of the conveyor belt 12 and thereby presence of the rip in the conveyor belt 12.
The belt separator 14 shown in Figure 2 includes a frame 16, in this example having a base portion 18, end portions 19, and first and second roller mount portions 20, 22 arranged to rotatably support respective first and second idler rollers 24, 26. The first and second idler rollers 24, 26 are connected to the base portion 18 at one of several pivot connections 23 and to a respective end portion 19 at one of several roller mount connections 25 through a support rod 29, the length of which between the end portion 19 and the roller mount portion 20, 22 is adjustable. In this way, the separation distance between the first and second idler rollers 24, 26 and the angle of inclination of the idler rollers 24, 26 is adjustable, for example by adjusting the location of the pivot connection 23 of the roller mount portions 20, 22, adjusting the location of the roller mount connection 25 to which the support rod 29 is connected, and/or adjusting the length of the support rod 29. Modifying the idler roller separation distance and/or the angle of inclination of the idler rollers 24, 26 enables the support locations of the conveyor belt 12 indicated by arrows 27 to be modified, and it will be understood that facilitating modification of the support locations 27 enables the profile change of the conveyor belt 12 in response to a belt rip to be made more detectible, particularly for rips that occur at skirt portions of the conveyor belt 12. It will also be understood that increasing the angle of inclination of the idler rollers 24, 26 has a squeezing effect on the conveyor belt 12.
The inventors have established that supporting the conveyor belt 12 towards longitudinal edges of the conveyor belt 12 increases the likelihood that a detectible profile change will occur in response to a rip in the conveyor belt 12 because profile changes are more likely to occur between the support points and less likely to occur outwardly of the support points. Accordingly, a rip occurring between the support points is more likely to be detectable than a rip outside of the support points. Also, the inventors have established that the squeezing effect caused by increasing the angle of inclination of the idler rollers 24, 26 also increases the likelihood that a detectible profile change will occur in response to a rip in the conveyor belt.
As shown in Figure 2, the belt separator 14 includes a void region 28 between the first and second idler rollers 24, 26. In a conventional belt idler assembly, a central idler roller would be provided that is rotatable about a generally horizontal axis, the central idler roller providing a degree of support for a belt in addition to the support provided by 2 side idler rollers. However, the inventors have established that the presence of a central idler roller reduces the amount of profile change that occurs in a belt when the belt is ripped and as a consequence a rip is more difficult to detect. Without the central idler roller, belt sag in response to a rip is more pronounced and therefore more likely to be detectible as a profile change.
The operative components 10 shown in Figure 1 include at least one sensor 30 that is configured to produce information indicative of a profile of the belt, which can then be used to determine whether a change of significance has occurred to the belt profile and thereby whether a rip is present in the belt. In this embodiment, a sensor assembly including several sensors, for example 8 sensors, is provided. The sensors may be any suitable sensors capable of producing information indicative of the profile of the belt, for example laser sensors, ultrasonic sensors, inductive sensors and/or radar sensors. In the present described embodiments, each sensor is arranged to detect distance to a conveyor belt in a field of view of the sensor without touching the conveyor belt, although it will be understood that alternatives are envisaged. For example, an arrangement may be provided whereby a roller mounted on a movable arm touches the conveyor belt and belt profile information is generated in response to movement of the arm. The operative components 10 also include a control unit 32 arranged to control and coordinate operations in the system and in particular implement an analysis engine 34 arranged to use signals produced by the sensors 30 to produce profile information that can be used by an operator to determine whether a rip is likely to be present. For example, in the present embodiment, the analysis engine 34 is arranged to automatically compare the detected profile with a reference profile for the conveyor belt 12 and to generate an alert signal when the detected profile exceeds a defined threshold compared to the default profile. The alert signal in this example is communicated directly to a conveyor belt control system, such as a PLC of the conveyor belt control system.
The analysis engine 34 may also be arranged to determine when a sensor is operating incorrectly, for example because the sensor blocked, and to trigger an alert to indicate that the sensor requires cleaning. The analysis engine 34 may also be arranged to produce information indicative of a visual representation of the belt profile for display to the operator, for example one or more plots indicative of the profile of the conveyor belt 12. For this purpose, the operative components 10 may also include a display 40 for displaying information to an operator indicative of the determined belt profile.
In this example, the control unit includes a processor 35 and the operative components 10 also include a data storage device 36 arranged to store programs and data used by the processor 35 to implement the desired functionality, and a memory 36 used by the processor to temporarily store programs and/or data during use.
The operative components 10 may include an alert unit 42 arranged to produce an alert, for example a visible or audible alert to an operator, when the analysis engine 34 generates an alert signal to indicate that the detected profile exceeds a defined threshold compared to a reference profile.
Referring to Figure 3, a plot 44 is shown that illustrates distance measurements obtained from a laser scanner that has a conveyor belt in a field of view of the laser scanner. Since the laser scanner measures distance from the laser scanner to an object across a field of view of the laser scanner, the plot 44 is therefore representative of the profile of the belt. As shown, while some noise is present, a general belt profile represented by broken line 45 can be seen.
Referring to Figure 4, a plot 46 is shown that illustrates distance measurements obtained from the laser scanner that has a ripped conveyor belt in the field of view of the laser scanner. The plot 46 includes a first profile portion 47 that corresponds to an upper portion of a side of the belt, and second profile portion 48 that corresponds to a lower portion of the belt. As shown, while some noise is present, it is clear that a discontinuity 50 is present between the first and second profile portions, and that the second profile portion 48 sags relative to the first profile portion 47. This indicates that a rip is present in the conveyor belt 12 between the first and second profile portions. A general ripped belt profile without noise is represented by broken line 51 .
Instead of a single laser scanner that is arranged to scan across the surface of the belt in order to produce a continuous belt profile, the sensor(s) 30 may take the form of one or more laser scanners or direct line sensors of the type arranged to provide distance data in separate channels.
In an example, 8 data plots 52, 54, 56, 58, 60, 62, 64 as shown in Figure 5 are produced by a plurality of laser scanners. Each plot corresponds to a different direction of view of a laser scanner and therefore each plot corresponds to a different portion of the section of belt that faces the laser scanners. In this example, therefore, a first plot 52 corresponds to an upper portion of a side of the belt and an eighth plot 64 corresponds to a lower portion of the side of the belt adjacent a central portion of the belt.
Referring to Figure 6, plots 66, 68 are shown that illustrate distance measurements obtained from an ultrasonic distance measuring device. A first plot 66 corresponds to a first ultrasonic sensor of the device and a second plot 68 corresponds to a second ultrasonic sensor of the device. As with the laser scanner described above, the ultrasonic device measures distance from the device to an object in the field of view of the device, and the plots 66, 68 are therefore representative of the profile of the belt at 2 locations. In this example, the first plot 66 corresponds to a lower portion of a side of the belt and the second plot 68 corresponds to an upper portion of the same side of the belt.
It can be seen from Figure 6 that a discontinuity 69 exists that represents a skirt rip. A center rip 67 is also detected. The second plot 68 does not detect the skirt rip because it is placed too high relative to the belt. In this way, the second ultrasonic sensor serves to provide a default plot of the belt that is less likely to respond to rips in the belt.
Figure 7 shows first and second plots 70, 72 for the respective first and second ultrasonic sensors over a longer time period than the plots 66, 68 shown in Figure 6.
Referring to Figure 8, diagrammatic representations of components of a belt rip detection system in accordance with an embodiment of the present invention are shown. In this example, a group of ultrasonic sensors 74 and radar sensors 76 are used to detect distance between the sensors and an adjacent belt 12. In this example, 6 ultrasonic sensors 74 and 2 radar sensors 76 are used. In this example, each ultrasonic sensor has a sensor field of view 80 corresponding to an approximate 200mm spot size directed upwardly towards the conveyor belt 12 and covering a different part of the conveyor belt 12, and each ultrasonic sensor 74 is arranged to provide a signal indicative of the minimum distance to an object in the field of view. It will however be understood that sensors with other spot sizes are envisaged.
Figure 9 shows the position of the conveyor belt 12 relative to the field of view 80 of a set of 8 ultrasonic sensors when a center rip 82 is present in the belt. Like and similar features are indicated with like reference numerals. As shown in Figure 9, a rip 82 in the centre of the conveyor belt 12 causes a central portion of the belt to sag, and as a consequence the distance measurements produced by the 4th and 5th sensors will detectably reduce. There may also be a small change in the distance measurements produced by the 3rd and 6th sensors, but most likely no identifiable change in the distance measurements produced by the 1st and 8th sensors. Figure 10 shows the position of the conveyor belt 12 relative to the field of view 80 of the sensors when a skirt rip 84 is present in the belt. As shown in Figure 10, a rip 82 in a skirt portion of the conveyor belt 12 causes minor sagging adjacent the skirt rip 84, and as a consequence the distance measurements produced by the 6th and 7th sensors will detectably reduce. There is likely to be no identifiable change in the distance measurements produced by the 1st, 2nd, 3rd, 4th, 5th and 8th sensors.
It will be appreciated, therefore, that a change in 1 or 2 of the 8 sensors can be used to indicate a rip in the conveyor belt 12.
Figure 1 1 shows plots 85 derived from the ultrasonic sensors 74 shown in Figure 8, the plots 85 corresponding to raw signals indicative of distance to the conveyor belt from each of the sensors 74. As each sensor 74 corresponds to a different field of view, the raw signal derived from each sensor 74 is indicative of whether a rip is present at a portion of the conveyor belt 12 in the field of view 80 of the sensor. Figure 1 1 also includes a plot 86 of conveyor belt load.
It will be appreciated that the profile of a belt with no rips changes significantly with changes in load, and accordingly in order to determine changes in belt profile in response to presence of a rip, it is necessary to generate reference data indicative of a loaded belt with no rips and to compare the measured profile data with the reference data in order to determine whether a rip is present. The reference data may be derived in any suitable way, for example using a mathematical model of a loaded belt or using a lookup table of reference sensor values for a loaded belt.
Figure 12 shows plots 88 that correspond to the ultrasonic sensor-derived plots 85 of Figure 1 1 after filtering, a plot 90 indicative of a load factor representing expected vertical deviation of the conveyor belt in response to an applied load represented by the load plot 86, and a plot 92 that includes pulses 94 indicative of detected rips in the conveyor belt 12.
By filtering the raw signals represented by the plots 85 in Figure 1 1 using the load factor plot 90, filtered signals represented by plots 88 are produced. Using the filtered signal plots 88, a rip on the conveyor belt 12 can be detected, and pulses 94 generated corresponding to the location(s) of the rip(s). In the present example, a generated pulse 94 is provided to a PLC of a conveyor belt control system. In a particular example, the following methodology is used.
Based on raw signals from the ultrasonic sensors, and prior to loading the conveyor belt, steady state sensor signals are produced that represent the profile of the conveyor belt when the conveyor belt is not loaded and when no rips are present in the belt. During use with the conveyor belt loaded, signals indicative of the loaded profile of the conveyor belt are obtained from the ultrasonic sensors. A transverse belt load factor based on a belt sag model is determined empirically from test data, and an error signal is determined by comparing the measured loaded profile signals with the expected loaded profile determined using the determined belt load factor. A moving average, for example of 10 successive determined values in the error signal, is then determined, and if there is a deviation greater than a defined threshold, for example a reduction in distance to the belt of 8mm or greater, a pulse 94 is added to the detected rip plot 92 to indicate that a rip is considered to be present in the conveyor belt 12.
Referring to Figures 13 to 15, diagrammatic representations of components of a belt rip detection system in accordance with an alternative embodiment of the present invention are shown. In this example, a plurality or group of laser sensor assemblies 100 are used to detect distance between the laser sensors and an adjacent belt, and each laser sensor assembly 100 includes 1 1 laser sensors. Each laser sensor is arranged to provide a signal indicative of the minimum distance to an object in the field of view located along a direct line of sight 102 extending generally horizontally from the sensor, and the sensors are configured so that the lines of sight 102 of the sensors are parallel.
Figure 13 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when no rip is present in the conveyor belt 12. As shown, the lowermost sensor is disposed such that the line of sight passes slightly under the central portion of the conveyor belt 12.
Figure 14 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when a center rip 104 is present in the belt. As shown in Figure 14, a rip 104 in the centre of the conveyor belt 12 causes a central portion of the belt to sag, and as a consequence the distance measurements produced by the first 4 sensors will detectably reduce. There will most likely be no identifiable change in the distance measurements produced by the 5th to 8th sensors. Figure 15 shows the position of the conveyor belt 12 relative to the lines of sight 102 of the sensors when a skirt rip 106 is present in the belt. As shown in Figure 15, a rip 106 in a skirt portion of the conveyor belt 12 causes minor sagging adjacent the skirt rip 106, and as a consequence the distance measurements produced by the 7th and 8th sensors will detectably reduce. There is likely to be no identifiable change in the distance measurements produced by the 1st to 6th and 9th to 1 1th sensors.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
Modifications and variations as would be apparent to a skilled addressee are determined to be within the scope of the present invention.

Claims

CLAIMS:
1 . A belt rip detection system for a conveyor including a conveyor belt, the system comprising:
a belt separator including at least two idler rollers, the belt separator arranged to support the conveyor belt on the at least two idler rollers, and to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator; and
at least one sensor arranged to produce information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt and thereby presence of the rip in the conveyor belt.
2. A belt rip detection system as claimed in claim 1 , wherein the belt separator includes first and second oppositely disposed inclined rollers arranged to support the conveyor belt, with no support for the conveyor belt between the first and second inclined rollers.
3. A belt rip detection system as claimed in claim 2, wherein the angle of inclination of the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable so as to facilitate an increase in the change in profile of the conveyor belt that occurs adjacent a rip in the conveyor belt.
4. A belt rip detection system as claimed in claim 2 or claim 3, wherein a spacing distance between the first and second rollers is adjustable.
5. A belt rip detection system as claimed in any one of the preceding claims, comprising a plurality of sensors, each sensor arranged to produce conveyor belt profile information for a substantially different portion of the conveyor belt, and the system arranged to use the profile information from any one or more of the sensors to determine whether a rip is present in the conveyor belt.
6. A belt rip detection system as claimed in any one of the preceding claims, wherein the at least one sensor includes at least one laser scanner arranged to scan across at least a section of the conveyor belt and produce distance information indicative of a profile of the conveyor belt section as the laser scans across the conveyor belt section.
7. A belt rip detection system as claimed in claim 6, wherein the laser scanner includes a plurality of laser sensors, each laser sensor arranged to scan across a substantially different portion of the conveyor belt section and produce distance information indicative of a profile of the conveyor belt portion as the laser scans across the conveyor belt portion.
8. A belt rip detection system as claimed in any one of claims 1 to 5, wherein the at least one sensor includes a plurality of direct line of sight sensors, each direct line of sight sensor arranged to provide a signal indicative of the distance to the conveyor belt along a different direct line of sight, wherein the lines of sight of the sensors are substantially parallel.
9. A belt rip detection system as claimed in claim 8, wherein the lines of sight extend generally horizontally.
10. A belt rip detection system as claimed in any one of the preceding claims, wherein the at least one sensor includes at least one ultrasonic sensor.
1 1 . A belt rip detection system as claimed in claim 10, comprising a plurality of ultrasonic sensors, each ultrasonic sensor arranged to cover a substantially different portion of the conveyor belt and produce distance information indicative of a profile of the conveyor belt portion.
12. A belt rip detection system as claimed in any one of the preceding claims, wherein the at least one sensor includes at least one radar sensor.
13. A belt rip detection system as claimed in any one of the preceding claims, wherein the at least one sensor includes at least one inductive sensor.
14. A belt rip detection system as claimed in any one of the preceding claims, comprising a display arranged to visually display the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt.
15. A belt rip detection system as claimed in any one of the preceding claims, wherein the system is arranged to automatically compare the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt with reference conveyor belt profile information and to generate an alert signal when the comparison indicates that a rip is present in the conveyor belt.
16. A belt rip detection system as claimed in claim 15, wherein the alert signal is communicated to a control system of the conveyor belt.
17. A belt rip detection system as claimed in claim 15 or claim 16, wherein the reference information comprises a load factor signal representing expected deviation of the conveyor belt in response to an applied load when the conveyor belt is not ripped, the load factor signal derived using a mathematical model of a loaded belt.
18. A belt rip detection system as claimed in any one of claims 15 to 17, wherein the reference information comprises a lookup table of reference sensor values for a loaded belt.
19. A method of detecting a rip in a conveyor belt of a conveyor, the method comprising:
providing a belt separator including at least two idler rollers;
supporting the conveyor belt on the at least two idler rollers, the belt separator arranged to induce a change in profile of the conveyor belt when a rip is present in the conveyor belt as a portion of the conveyor belt including the rip passes over the belt separator; and
using at least one sensor to obtain profile information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt and thereby presence of the rip in the conveyor belt.
20. A method as claimed in claim 19, wherein the belt separator includes first and second oppositely disposed inclined rollers, and the method comprises using the first and second oppositely disposed inclined rollers to support the conveyor belt, with no support for the conveyor belt between the first and second inclined rollers.
21 . A method as claimed in claim 20, wherein the angle of inclination of the first and second rollers is adjustable and thereby support points of the conveyor belt are adjustable so as to facilitate an increase in the change in profile of the conveyor belt that occurs adjacent a rip in the conveyor belt.
22. A method as claimed in claim 20 or claim 21 , wherein a spacing distance between the first and second rollers is adjustable.
23. A method as claimed in any one of claims 19 to 22, comprising using a plurality of sensors to obtain profile information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt a plurality of sensors, each sensor arranged to produce conveyor belt profile information for a substantially different portion of the conveyor belt, and using the profile information from any one or more of the sensors to determine whether a rip is present in the conveyor belt.
24. A method as claimed in any one of claims 19 to 23, comprising using at least one laser scanner to scan across at least a section of the conveyor belt and produce distance information indicative of a profile of the conveyor belt section as the laser scans across the conveyor belt section.
25. A method as claimed in claim 24, wherein the laser scanner includes a plurality of laser sensors, and the method comprises using each laser sensor to scan across a substantially different portion of the conveyor belt section and produce distance information indicative of a profile of the conveyor belt portion as the laser scans across the conveyor belt portion.
26. A method as claimed in any one of claims 19 to 23, wherein the at least one sensor includes a plurality of direct line of sight sensors, and the method comprises using each direct line of sight sensor to provide a signal indicative of the distance to the conveyor belt along a different direct line of sight, wherein the lines of sight of the sensors are substantially parallel.
27. A method as claimed in claim 26, wherein the lines of sight extend generally horizontally.
28. A method as claimed in any one of claims 19 to 27, wherein the at least one sensor includes at least one ultrasonic sensor.
29. A method as claimed in claim 28, comprising providing a plurality of ultrasonic sensors, and using each ultrasonic sensor to cover a substantially different portion of the conveyor belt and produce distance information indicative of a profile of the conveyor belt portion.
30. A method as claimed in any one of claims 19 to 29, wherein the at least one sensor includes at least one radar sensor.
31 . A method as claimed in any one of claims 19 to 30, wherein the at least one sensor includes at least one inductive sensor.
32. A method as claimed in any one of claims 19 to 31 , comprising displaying the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt.
33. A method as claimed in any one of claims 19 to 32, comprising automatically comparing the information indicative of the change in profile of the conveyor belt adjacent a rip in the conveyor belt with reference conveyor belt profile information and generating an alert signal when the comparison indicates that a rip is present in the conveyor belt.
34. A method as claimed in claim 33, comprising communicating the alert signal to a control system of the conveyor belt.
35. A method as claimed in claim 33 or claim 34, wherein the reference information comprises a load factor signal representing expected deviation of the conveyor belt in response to an applied load when the conveyor belt is not ripped, and the method comprises deriving the load factor signal using a mathematical model of a loaded belt.
36. A method as claimed in any one of claims 33 to 35, wherein the reference information comprises a lookup table of reference sensor values for a loaded belt.
PCT/AU2017/050838 2016-08-18 2017-08-09 A belt rip detection system WO2018032040A1 (en)

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