Bolt tension detection system

Abstract

A bolt tension detection system for an industrial part having a front surface (14), a rear surface (16) and one or more bolts (34) extending from the rear surface (16) to engage with a wall of an industrial system. A recess (20) in the rear wall (16) is filled with a fill material (22) and a pressure sensor (24) is provided within the recess (20). A member (26) is embedded within the fill material (22) and has an inner end (28) adjacent the pressure sensor (24) and an outer end (29) extending beyond the fill material (22) to engage the wall of the industrial system when the industrial part (12) is bolted to the wall, thereby applying pressure to the pressure sensor (24).

Description

[0001] “Bolt Tension Detection System”

[0002] Field of the Invention

[0003]

[0001] The present invention relates to a bolt tension detection system for use on industrial parts such as wear plates of the type used in conveyor systems.

[0004] Background to the Invention

[0005]

[0002] Conveyor systems use a range of plates designed to guide material along the conveyor belt. Wear plates are placed at certain locations such that material on the conveyor engages with a front face of the wear plate in order to guide the material.

[0006]

[0003] Wear plates of this type are generally bolted in place. The rear surfaces of the wear plates include bolts which are passed through holes in the wall on which the liner plate is mounted. Due to the impacts on the wear plate during use, it is possible in some circumstances for the bolt to be damaged and break. This can result in loosening of the wear plate, causing further damage through movement, and the wear plate possibly coming free. Such a situation can potentially cause significant damage within the conveyor system.

[0007]

[0004] The present invention relates to a bolt tension detection system for use with such wear plates in order provide an alert to operators of the system should a bolt on a wear plate break or loosen.

[0008] Summary of the Invention

[0009]

[0005] According to one aspect of the present invention there is provided a bolt tension detection system for an industrial part having a front surface, a rear surface and one or more bolts extending from the rear surface to engage with a wall of an industrial system, the bolt break detection system comprising: a recess in the rear wall of the industrial part filled with a fill material; a pressure sensor provided within the recess; a member embedded within the fill material having an inner end adjacent the pressure sensor and an outer end extending outwardly from an upper surface of the fill material; and a central monitoring system in communication with the pressure sensor; wherein the outer end of the member engages with the wall of the industrial system when the industrial part is bolted to the wall, thereby applying pressure to the pressure sensor such that, should one of the bolts break or loosen, the change in pressure applied to the pressure senor may be detected by the central monitoring system.

[0010]

[0006] Preferably the pressure sensor comprises a conductive layer such that resistance of the conductive layer changes in the event one of the bolts breaks or loosens.

[0011]

[0007] Preferably the conductive layer is mounted adjacent an inner surface of the recess.

[0012]

[0008] Preferably the conductive layer is connected by conductive tracks to a monitoring unit mounted relative the wear plate, the monitoring unit including a transmitter to transmit information regarding resistance of the conductive layer to the central monitoring system.

[0013]

[0009] Preferably the member is cylindrical.

[0014]

[0010] In one embodiment, the member includes knurling on an outer surface to engage with the fill material.

[0015]

[0011] Preferably the industrial part comprises a wear plate and a wear sensor is provided within the recess comprising a flexible sheet and the pressure sensor is provided on the flexible sheet.

[0012] Preferably the wear sensor includes a plurality of flexible arms having conductive tracks connected to the monitoring unit, the arms extending through to the front surface of the wear plate and edge surfaces of the wear plate to detect wear of the front and edge surfaces.

[0016]

[0013] Preferably the conductive layer is provided on a substrate provided on an inner surface of the recess.

[0017]

[0014] Preferably a protective layer is provided between the conductive layer and the member.

[0018]

[0015] In one embodiment, a pressure plate is provided between the outer end of the member and the wall of the industrial system.

[0019]

[0016] Preferably the pressure plate extends across the outer ends of a plurality of the members.

[0020]

[0017] Preferably the pressure plate includes a plurality of legs received into the fill material.

[0021] Brief Description of the Drawings

[0022]

[0018] The invention will now be described, by way of example, with reference to the following drawings, in which:

[0023]

[0019] Figure 1 is an upper perspective view of a wear plate incorporating the bolt tension detection system of the present invention prior to filling the recess in the rear surface of the wear plate;

[0024]

[0020] Figure 2 is an upper perspective view of the wear plate of Figure 1 with the recess filled; and

[0025]

[0021] Figure 3 is a side cross sectional view of a portion of the wear plate showing the pressure sensor;

[0026]

[0022] Figure 4 is an upper perspective view of a wear plate incorporating a second embodiment of a bolt tension detection system in accordance with the present invention, prior to filling the recess in the rear surface of the wear plate;

[0023] Figure 5 is a top view of the wear plate of Figure 4;

[0024] Figure 6 is an upper perspective view of the wear plate of Figure 4 with the backing plate removed

[0027]

[0025] Figure 7 is a top view of the wear plate of Figure 6;

[0028]

[0026] Figure 8a is a top view of one of the backing plates and associated pressure sensors;

[0029]

[0027] Figure 8b is a side view of the backing plate and pressure sensors of Figure 8a;

[0030]

[0028] Figure 8c is a top view of one the backing plates;

[0031]

[0029] Figure 8d is a side view of the backing plate;

[0032]

[0030] Figure 8e is a top view of one of the pressure sensors;

[0033]

[0031] Figure 8f is a top view of the member provided to engage with the pressure sensor; and

[0034]

[0032] Figure 8g is a side view of the member of Figure 8d.

[0035] Detailed Description of Preferred Embodiments

[0036]

[0033] Referring to the Figures, there is shown a bolt tension detection system for using on an industrial part such as a wear plate 12. The wear plate 12 comprises a standard wear plate of the type which may be used to line a chute in a conveyor system. The wear plate 12 includes a front surface 14 against which material within the chute engages and a rear surface 16 which is secured adjacent a wall of the chute.

[0037]

[0034] In the embodiment shown, the wear plate 12 is generally rectangular such that the front and rear surfaces 14 and 16 are rectangular and joined by an edge surface 18 around the periphery thereof. It will be appreciated however that other shapes of wear plates 12 may incorporate the bolt tension detection system of the present invention.

[0038]

[0035] The wear plate 12 includes a recess 20 in the rear surface 16 thereof. The recess 20 is to be filled in use with a fill material 22 (as can be seen in Figure 1 ). The fill material 22 comprises a compound to poured into the recess 20 in a liquid form, which will then set to fill the recess 20 such that an upper surface of the fill material 22 is located adjacent the rear surface 16 of the wear plate 12.

[0039]

[0036] The recess 20 is to be provided with one or more pressure sensors 24. The pressure sensors 24 are to be secured within the fill material 22 adjacent an inner surface of the recess 20. In embodiment shown, there are provided four such pressure sensors 24 provided generally adjacent each of the corners of the recess 22. However, it will be appreciated that alternative numbers of pressure sensors 24 and different positions thereof may be used.

[0040]

[0037] The bolt tension detection system is provided with a member 26 secured within the fill material 22 adjacent each of the pressure sensors 24. In embodiment shown, each of the members 26 is generally cylindrical in shape and has an inner end 28 located adjacent the pressure sensor 24 and an outer end 29. The outer end 29 of each of the members 26 protrudes beyond the upper surface of the material 22 and above the rear surface 16 of the wear plate 12. The member 26 may include knurling 30 on an outer surface thereof to assist with engagement with the fill material 22.

[0041]

[0038] The pressure sensors 24 each comprise a conductive layer 32 positioned adjacent the inner end 28 of the respective member 26. The conductive layer 32 is connected to a central monitoring system such that the central monitoring system receives information regarding the resistance of the conductive layer 32. As the outer end 29 of the member 26 protrudes beyond the rear surface 16 of the wear plate 12, as the wear plate 12 is attached to a wall (not shown) of a conveyor chute by bolts 34, tightening the bolts 34 pushes the outer end 29 of the member 26 into the chute wall. The inner end 28 of the member 26 is thereby pushed against the conductive layer 32.

[0042]

[0039] Changes in the pressure applied by the member 26 against the conductive layer 32 changes the resistance of the conductive layer 32. Should one of the bolts 34 break in use, the pressure applied against the outer ends 29 of the members 26 will be reduced. This will in turn reduce the pressure applied to the conductive layer 32, thereby changing the resistance of the conductive layer 32 which may be detected by the central monitoring system.

[0043]

[0040] In embodiment shown, the wear plate 12 is provided also with a wear sensor 36. The wear sensor 36 comprises a flexible sheet 44 of material having a plurality of flexible arms 38. The arms 38 includes conductive tracks along the length thereof and are provided to extend through holes 40 in the wear plate 12 extending to the front surface 14 and also through slots 42 extending to the edge surface 18. As the front surface 14 and the edge surface 18 wear down, the ends of the arms 38 are worn down which may be detected by the central monitoring system to monitor the wear of the wear plate 12.

[0044]

[0041] The wear sensor 36 is connected to a monitoring unit (not shown) provided on the wear plate 12. The monitoring using may be provided in a housing secured to one of the bolts 34. The monitoring unit includes a transmitter to send information received from the wear sensor 36 to the central monitoring system.

[0045]

[0042] The conductive layer 32 of the pressure sensor 24 is provided in the embodiment shown in conjunction with the wear sensor 36. As can be seen in Figure 3, the conductive layer 32 is provided on top of the flexible sheet 44 of the wear sensor 36 such that conductive tracks connecting the conductive layer 32 back to the monitoring unit provide the means for transmitting information regarding resistance of the conductive layer 32 to the central monitoring system. The wear sensor 36 and the conductive layer 32 are provided on top of a substrate 46 secured to an inner surface of the recess 20 (as can be seen in Figure 3). A protective layer 48 is provided on top of the conductive layer 32 between the conductive layer 32 and the inner end 28 of the member 26.

[0046]

[0043] In use, a plurality of pressure sensors 24 in the form of conductive layers 32 are provided adjacent the inner surface of the recess 20 such that the members 26 change the resistance of the conductive layers 32 as the wear plate 12 is tightened into position. Should to any of the bolts 34 break or loosen during use, the resistance of the conductive layers 32 will change and this change in resistance may be detected by the central monitoring system. The central monitoring system may then provide an alert to operators of the system to allow for appropriate maintenance of the wear plate 12 before the wear plate 12 breaks free from the conveyor chute, potentially causing further damage.

[0047]

[0044] Figure 4 to 8 show a further embodiment of a bolt tension detection system in accordance with the present invention. The bolt tension detection system of Figures 4 to 8 is similar to the previous embodiment and like reference numerals are used to denote like parts.

[0048]

[0045] In the embodiment of Figures 4 to 8, the pressure sensors 24 are provided on separate sensor arms 50. In the embodiment shown, there are provided four such sensor arms 50. The pressure sensors 24 are provided on first ends of the sensor arms 50 and second ends thereof are connect back to a central region of the wear sensor 36. In the embodiment shown, each of the sensor arms 50 extends outwardly from a centre of the wear sensor 36 toward a corner of the wear plate 12.

[0049]

[0046] Further, the bolt tension detection system is provided with one or more pressure plates 52. Each of the pressure plates 52 comprises a planar member to be mounted adjacent the rear surface 16 of the wear plate adjacent the outer end 29 of one or more of the pressure sensors 24. In the embodiment shown, there are provided two pressure plates 52, each extending across the outer end 29 of a pair of the members 26. The pressure plates 52 in this embodiment are annular in shape.

[0050]

[0047] The pressure plates 52 each include a plurality of legs 54 extending outwardly from a first side 56 thereof. The legs 54 are received in use in the fill material 22. A second side 57 of the pressure plate 52 engages against an adjacent wall of the industrial system such that, when the wear plate 12 is secured in use, the pressure plate 52 applies force to the member 26 to force it against the pressure sensor 24.

[0048] It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention.

Claims

Claims1. A bolt tension detection system for an industrial part having a front surface, a rear surface and one or more bolts extending from the rear surface to engage with a wall of an industrial system, the bolt break detection system comprising: a recess in the rear wall of the industrial part filled with a fill material; a pressure sensor provided within the recess; a member embedded within the fill material having an inner end adjacent the pressure sensor and an outer end extending outwardly from an upper surface of the fill material; and a central monitoring system in communication with the pressure sensor; wherein the outer end of the member engages with the wall of the industrial system when the industrial part is bolted to the wall, thereby applying pressure to the pressure sensor such that, should one of the bolts break or loosen, the change in pressure applied to the pressure senor may be detected by the central monitoring system.

2. A bolt tension detection system in accordance with claim 1 , wherein the pressure sensor comprises a conductive layer such that resistance of the conductive layer changes in the event one of the bolts breaks or loosens.

3. A bolt tension detection system in accordance with claim 2, wherein the conductive layer is mounted adjacent an inner surface of the recess.

4. A bolt tension detection system in accordance with claim 2 or 3, wherein the conductive layer is connected by conductive tracks to a monitoring unit mounted relative the wear plate, the monitoring unit including a transmitter to transmit information regarding resistance of the conductive layer to the central monitoring system.

5. A bolt tension detection system in accordance with claim 4, wherein the member is cylindrical.

6. A bolt tension detection system in accordance with claim 5, wherein the member includes knurling on an outer surface to engage with the fill material.

7. A bolt tension detection system in accordance with any one of the preceding claims, wherein the industrial part comprises a wear plate and a wear sensor is provided within the recess comprising a flexible sheet and the pressure sensor is provided on the flexible sheet.

8. A bolt tension detection system in accordance with claim 7, wherein the wear sensor includes a plurality of flexible arms having conductive tracks connected to the monitoring unit, the arms extending through to the front surface of the wear plate and edge surfaces of the wear plate to detect wear of the front and edge surfaces.

9. A bolt tension detection system in accordance with any one of claims 2 to 8, wherein the conductive layer is provided on a substrate provided on an inner surface of the recess.

10. A bolt tension detection system in accordance with claim 9, wherein a protective layer is provided between the conductive layer and the member.

11. A bolt tension system in accordance with any one of the preceding claims, wherein a pressure plate is provided between the outer end of the member and the wall of the industrial system.

12. A bolt tension system in accordance with claim 11 , wherein the pressure plate extends across the outer ends of a plurality of the members.

13. A bolt tension system in accordance with claim 11 or 12, wherein the pressure plate includes a plurality of legs received into the fill material.

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