WO2023115174A1

WO2023115174A1 - Arrangement and method for automatically detecting roller replacement in belt conveyors

Info

Publication number: WO2023115174A1
Application number: PCT/BR2022/050359
Authority: WO
Inventors: Tiago CARRIL PUIG; Bruno BASSO BRANDANI
Original assignee: Bosch Soluções Integradas Brasil Ltda
Priority date: 2021-12-22
Filing date: 2022-09-08
Publication date: 2023-06-29

Abstract

Problem to be solved: To provide a solution for automatically detecting roller replacement for belt conveyors. Solution to the problem: An arrangement is provided comprising at least one support structure (50) supporting rollers (90), the support structure (50) comprising several recesses (51) in which are mounted respective axles of the rollers (90), which are associated with a sensor element (85) associated with a respective processing module (60), the sensor element (85) being arranged at one end (91) of the respective roller (90), juxtaposed to the respective recess (51) to which the respective axle of the roller (90) is mounted; the respective processing module (60) is arranged in the respective support structure (50); the sensor element (85) includes a first electric conductor (81) that can be electrically connected to the electric connector (70), which is functionally associated with the processing module (60), the electric connector (70) being attached to the respective support structure (50).

Description

"ARRANGEMENT AND METHOD FOR AUTOMATIC DETECTION OF ROLL CHANGE IN BELT CONVEYORS"

Field of Invention

[001] The present invention relates to belt conveyors and, more specifically, to an arrangement and a method for automatically detecting roll change in these belt conveyors.

Fundamentals of the Invention

[002] Belt conveyors are widely used in applications where there is a need to move materials over long distances and/or in large volumes. In the mining environment, for example, it is common to use long-distance belt conveyors to move the ore between the different stages of the process.

[003] Figures 1.1 and 1.2 show a simplified configuration of a belt conveyor, composed of a driving pulley T, a tensioning pulley 2', a conveyor belt (or belt) 3' and load rollers 4' and return. Rollers 4', in turn, are supported on support structures (stands) and the set between the latter, stands and rolls 4', are called rollers 5'.

[004] Each roller 5' comprises some rollers 4' commonly arranged in the shape of a 'U' letter, to properly accommodate the material to be transported. Typically, in the mining environment, 5' rollers with three 4' load rollers and two 4' return rollers are observed, but other configurations are also possible.

[005] To support the belt/conveyor and the transported material, it is common for the loading stands to be spaced 1.5m apart and the return ones to be 3m apart. Other distances are also possible and vary according to the project, however on all long distance conveyors it is common to have thousands of 4' rolls per kilometer.

[006] Eventually, the 4' rollers fail, or are on the verge of failing, and therefore that need to be replaced. Some systems for monitoring and/or predicting hoisting of rollers on belt conveyors are already known from the state of the art, such as those described in documents BR102018577310, US2011137587, EP2392728, CL2020002296, CL2020002966, WO12122597A1, US2020256745, WO15 013758 and WO16019431, by example.

[007] Documents WO12122597A1 , US2020256745 , WO15013758 and WO1 6019431 , each with its particularity, already reveal monitoring systems that comprise respective sensors arranged next to the respective rollers, or on easels/supports, or on the conveyor belt for the purpose of monitoring and maintenance, relative to the replacement of the respective roller. These documents do not, however, state that the sensor assembly is "bipartite" (in WO12122597A1, for example, see the assembly indicated by reference "40", which includes the sensitive element together with the microcontroller and antenna, which is integrally arranged in a single "location"). Said documents also do not foresee that a hypothetical loss of signal related to that sensor would be related to a change of a specific roll to which the respective sensor assembly is associated.

[008] Document US2011137587, in turn, more relevant than the others, already reveals a sensor arrangement for monitoring the condition of roller(s) of a conveyor belt, for maintenance purposes, said sensor arrangement being "bipartite" , including a sensitive element associated with a communication module, both the sensitive element (indicated by reference “85”) and the communication module (indicated by reference “84”) are placed next to the roller and the communication between them is it is wireless, that is, there is no physical (data) connection between these components.

[009] Document EP2392728, in turn, now considered the most relevant, despite being a totally different application, already reveals a sensor arrangement for monitoring the condition of roll(s), for maintenance purposes, said sensor arrangement (indicated by reference “26”) being “bipartite”, including at least one sensitive element (indicated by reference “30”) electrically associated with a processing module (indicated by reference “32”) by means of a wiring electrical connector (indicated by reference “28”) and an electrical connector (see “slip ring connector” - parag. 0041 of this document), the sensitive element being placed on the circumferential surface of the roll, next to a cover (indicated by reference “ 24"), while the processing module is arranged outside the roll.

[010] The constructive arrangement of the solution of this EP2392728 document is very similar to that of the present invention, however, depending on the arrangement of the sensitive elements on the circumferential surface of the roll, the arrangement of the electrical wiring between the sensitive element and the processing module can be harmed. Furthermore, said document EP2392728, as well as US2011137587, are also silent in predicting that a hypothetical loss of signal relative to a respective sensor (sensitive element) would be related to a change of the respective roll to which said sensor assembly is associated.

[011] In summary, none of the documents above discusses an automatic roll change detection method for belt conveyors. And this is precisely because no constructive arrangement of the solutions in these documents is exactly identical to what will be presented below, not even that of document EP2392728, now considered the most similar.

[012] Thus, and although the solutions described above prove to be functional for the purposes for which they were made feasible, it is noted that there are still gaps in the state of the art with regard to the provision of a sufficiently robust, efficient and reliable solution, with regard to an automatic roll change detection method for belt conveyors, through a simple constructive arrangement that even allows the retrofit of already validated and currently produced systems. [013] It is based on this scenario that the invention in question arises.

Objectives of the Invention

[014] Thus, it is a fundamental objective of the invention in question to reveal a constructive arrangement that allows to execute an automatic detection method of roll change for belt conveyors;

[015] More specifically, it is the objective of the present invention to describe a sufficiently robust, efficient and reliable solution regarding the detection of roll change in conveyor belts;

[016] Another objective is to describe a simple, low-cost and practical solution, applicable to already designed belt conveyors;

[017] In other words, it is the objective of the present invention to design a solution that allows the retrofit of already validated and currently produced systems;

Summary of the Invention

[018] The objectives summarized above are achieved by means of an arrangement for automatic detection of roller exchange on belt conveyors, of the type that includes at least one support structure that supports respective rollers, said at least one support structure including a plurality of recesses where respective axes of the rollers are mounted, said rollers being operatively associated with at least one sensitive element, said at least one sensitive element being associated with a respective processing module, said at least one sensitive element being arranged in a end of the respective roll, juxtaposed to the respective recess to which the respective roll axis is bearing; the respective processing module is disposed on the respective support structure; said at least one sensing element includes a first electrical conductor capable of electrically connecting to an electrical connector; said electrical connector being operatively associated with said processing module; and said electrical connector being fixed to the respective support structure. [019] Preferably, according to the present invention, each roller comprises at least two sensitive elements arranged, each one, at one end of the respective roller.

[020] The present invention also relates to the method for automatic detection of roller exchange on belt conveyors, of the type that includes at least one support structure that supports respective rollers, said at least one support structure includes a plurality of recesses where respective axes of the rollers are mounted, said rollers being operatively associated with at least one sensitive element and said at least one sensitive element being associated with a respective processing module, said method comprising the following steps: disconnecting, from the electrical connector, the first electrical conductor of a sensitive element of a respective roller; respective processing module to detect said disconnection through the interpretation of the loss of electrical signal from said sensitive element; respective processing module send a signal to a central platform informing that there was a disconnection; the central platform registers that the respective roll has been removed from the belt conveyor.

[021] Preferably, said method for automatic detection of roll change on belt conveyors also includes the following subsequent steps: connecting, in the electrical connector, a first electrical conductor of the sensitive element of a new roll; respective processing module to detect said connection by restoring the electrical signal from said sensitive element of the new roll; respective processing module send a signal to a central platform informing that there was a new connection; the center deck registers that the respective new roll has been installed on the belt conveyor.

[022] Also preferably, the detection of disconnection through the interpretation of the loss of electrical signal, through the respective processing module, only occurs upon the fact that there is loss of electrical signal of at least two sensitive elements associated with the same roll.

Brief Description of the Drawings

[023] The invention in question is now detailed based on the illustrative figures listed below:

[024] Figures 1.1 and 1.2 illustrate a side view and a cross-sectional view, respectively, of a belt conveyor, according to the state of the art;

[025] Figure 2 illustrates a perspective view of the arrangement for automatic detection of roll change in belt conveyors, according to the present invention.

Detailed Description of the Invention

[026] Thus, with a focus on achieving the aforementioned objectives, the present invention relates to an arrangement for automatic detection of roller exchange on belt conveyors, of the type that includes at least one support structure 50 that supports respective rollers 90, said at least one support structure 50 includes a plurality of recesses 51 defining bearings where respective axes of rollers 90 are mounted, said rollers 90 being operatively associated with at least one sensitive element 85, said at least one sensitive element 85 being associated with a respective processing module 60.

[027] Particularly, according to the present invention, said at least one sensitive element 85 is arranged at one end 91 of the respective roller 90 and, more specifically, next to a flat face of the axis of the respective roller 90, juxtaposed to the respective recess 51 to which the respective roller axis 90 is bearing and projecting beyond (outwards) the respective recess 51, while the respective processing module 60 is arranged in the respective support structure 50.

[028] Furthermore, said at least one sensitive element 85 includes a first electrical conductor 81 capable of electrically connecting to an electrical connector 70, which is operatively associated with said processing module 60. Said electrical connector 70 is fixed to the respective support structure 50.

[029] Preferably, said processing module 60 is also operatively associated with a second electrical conductor 61 also capable of connecting to the electrical connector 70. In summary, the electrical connector 70 is responsible for providing the electrical connection between the sensitive element 85 and the processing module 60. The first and second electrical conductors 81, 61 are preferably electrical wiring. In this sense, it is clear that the electrical connector 70, together with the electrical conductors 81, 61 are responsible for providing communication, via wire/cable, between the sensitive element 85 and the processing module 60.

[030] Thus, it is noted that the arrangement of the present invention comprises a bipartite sensor assembly, since it comprises two distinct components, namely, a sensitive element 85 and a processing module 60, and said components are installed in different parts of the easel, the first in a modular/interchangeable part (the roller 90), and the second in a fixed part (the support structure 50). Furthermore, it is also noted that the sensing element 85 is disposed adjacent to the end 91 of the roller 90 and projects beyond the recess 51 of the support structure 50.

[031] According to this arrangement, the layout of the electrical wiring that comes out of the sensitive element 85, therefore, is more easily installed, is shorter and, consequently, has lower manufacturing costs, as well as a simpler arrangement, practical, reliable and robust.

[032] Preferably, each roller 90 can comprise at least two sensitive elements 85 arranged, each one, at one end 91 of the respective roller 90.

[033] Here, it should be noted that each roller 90 basically consists of a three-dimensional solid analogous to a prism with a circular base, that is, a cylinder. Per “end 91 of roll 90” means the longitudinal ends, that is, the circular bases of this solid.

[034] Having described the arrangement for automatic detection of roll change in belt conveyors according to the present invention, below follows a brief description of the method that governs its operating principle.

[035] In this sense, said method comprises the following steps: disconnect, from the electrical connector 70, the electrical conductor 81 of a sensitive element 85 of a respective roller 90; respective processing module 60 to detect said disconnection through the interpretation of the loss of electrical signal from said sensitive element 85; respective processing module 60 send a signal (via wireless, preferably, through an antenna - not shown) to a central platform (directly or indirectly) informing that there was a disconnection; the central platform registers that the respective roll 90 has been removed from the belt conveyor.

[036] According to the above steps, said central platform is able to "realize" that a defective roller 90 - or about to fail - is being replaced and the monitoring of that specific roller 90 can be ceased.

[037] Then, and for the purpose of starting a new monitoring period, a new roller 90 to be installed, obviously, said method for automatic detection of roller exchange on belt conveyors comprises the following complementary steps: connect, on the electrical connector 70, an electrical conductor 81 from the sensing element 85 of a new roller 90; respective processing module 60 detecting said connection by restoring the electrical signal coming from said sensitive element 85 of the new roller 90; respective processing module 60 send a signal (via wireless, preferably, through an antenna - not shown) to a central platform (directly or indirectly) informing that there was a new connection; the center platform registers that the respective new roller 90 has been installed on the belt conveyor. [038] Thus, said central platform (or server) is able to “perceive” that the roll 90 that presented defects - or was about to present - has already been replaced by a new roll 90 and a new monitoring period (for the new roll 90 ) must be started.

[039] Here, it is worth mentioning that sending the signal from the processing module 60 to the central platform can be done directly or indirectly. This indirect way means that the signal can pass through intermediary components such as signal concentrators, amplifiers, gateways or other electronic components.

[040] Preferably, the detection of disconnection through the interpretation of the loss of electrical signal, through the respective processing module 60, only occurs when there is loss of electrical signal from at least two sensitive elements 85 associated with the same roller 90, in a “simultaneous” manner, that is, within a time window delimited by a predetermined value, for example, three hundred seconds (sufficient time for dismantling the roller 90 from the support structure 50), thus differentiating the event of a roll change of a possible loss of connection due to damage to the cables (electrical wiring).

[041] This is because, as the damage and breakage of the cables is a rare event, the interruption of the signal of the two sensitive elements 85 “simultaneously” is much more likely to be associated with the intentional removal of the respective roll 90, than a simultaneous breakage of these cables.

[042] The information from the sensor assembly (sensitive element 85 together with the processing module 60), in combination with the central platform, allows the user to know precisely the date of exchange of each roll, calculate the time until failure, generate reports with statistics, reliability curves, indication of stretches with the highest incidence of failures, among others. [043] With this data, the user will be able to compare durability specifications of their 90 roller suppliers, compare between different brands/models, calculate the best time for preventive maintenance and, thus, manage their assets in a more systematized way.

[044] It is important to emphasize that the above description has the sole purpose of describing, by way of example, the particular embodiment of the invention in question. Therefore, it becomes clear that modifications, variations and constructive combinations of elements that perform the same function in substantially the same way to achieve the same results, remain within the scope of protection delimited by the attached claims.

Claims

1 . Arrangement for automatic detection of roll change on belt conveyors, of the type that includes at least one support structure (50) supporting respective rolls (90), said at least one support structure (50) including a plurality of recesses ( 51) where respective axes of the rollers (90) are mounted, said rollers (90) being operatively associated with at least one sensitive element (85), said at least one sensitive element (85) being associated with a respective processing module (60 ), said arrangement being CHARACTERIZED by the fact that: said at least one sensitive element (85) is arranged at one end (91) of the respective roller (90), juxtaposed to the respective recess (51) to which the respective axis is bearing of the roll (90); the respective processing module (60) is arranged in the respective support structure (50); said at least one sensing element (85) includes a first electrical conductor (81) capable of electrically connecting to an electrical connector (70); said electrical connector (70) being operatively associated with said processing module (60); said electrical connector (70) being fixed to the respective support structure (50).

2. Arrangement for automatic detection of roll change on belt conveyors, according to claim 1, characterized by the fact that each roll (90) comprises at least two sensitive elements (85) arranged, each one, at one end ( 91) of the respective roller (90).

3. Method for automatic detection of roll change on belt conveyors, of the type that includes at least one support structure (50) supporting respective rolls (90), said at least one support structure (50) including a plurality of recesses (51) where respective axes of the rollers (90) are mounted, said rollers (90) being operatively associated with at least one sensitive element (85) and said at least one sensitive element (85) being associated with a respective processing module (60), said method being CHARACTERIZED by the fact that it comprises the following steps: disconnecting, from the electrical connector (70), the first electrical conductor (81 ) of a sensitive element (85) of a respective roller (90); respective processing module (60) detecting said disconnection through the interpretation of the loss of electrical signal from said sensitive element (85); respective processing module (60) send a signal to a central platform informing that there was a disconnection; the central platform registers that the respective roll (90) has been removed from the belt conveyor.

4. Method for automatic detection of roll change in belt conveyors, according to claim 3, characterized by the fact that it comprises the following steps: connecting, in the electrical connector (70), a first electrical conductor (81) of the element sensitive (85) of a new roll (90); respective processing module (60) detecting said connection by restoring the electrical signal from said sensitive element (85) of the new roll (90); respective processing module (60) send a signal to a central platform informing that there was a new connection; the central platform registers that the respective new roller (90) has been installed on the belt conveyor.

5. Method for automatic detection of roll change on belt conveyors, according to claim 3, CHARACTERIZED by the fact that: disconnection detection through the interpretation of the loss of electrical signal, by means of the respective processing module (60) only occurs when there is loss of electrical signal from at least two sensitive elements (85) associated with the same roller (90).