Conveyor system

Abstract

A conveyor system supports a conveyor belt (102) in a trough shape by a transition portion (145) in which the height of the conveyor belt (120) varies, the transition portion (145) including an upward height variation and a subsequent downward height variation.

Description

Technical Field

[0001] The present invention relates to a conveyor system.

[0002] The present invention relates particularly, but by no means exclusively, to a conveyor belt redirection system.

[0003] The present invention particularly, but by no means exclusively, relates to a conveyor belt redirection system configured to redirect a conveyor belt of a conveyor system.

[0004] background

[0005] Conveyor systems are used in the resource industries to transport material between different stages and / or different components of the production workflow. For example, in an iron ore production facility, one or more conveyor systems are typically used to transport ore to / from crushing equipment, transport trains, and equipment at port facilities. Such conveyor systems are critical to the production process, and therefore any downtime of the conveyor system can have a significant impact on the production capacity of the production facility, and thereby on the operating efficiency and costs of the production facility.

[0006] Conveyor systems may be subject to various constraints that affect, to some extent, the profile of the conveyor system and / or the conveyor belt loops of the associated conveyor system. For example, a shuttle conveyor system typically includes a transition section where the conveyor belt descends from a linear belt path at one height (i.e., a belt path without vertical curvature) to another linear belt path at a lower height. This is because a portion of the shuttle of the shuttle conveyor is retracted below the upstream idler when the shuttle moves from the extended position to the retracted position. The idlers of the shuttle need to be at a lower height than the idlers upstream of the shuttle so that they can move below the upstream idlers as the shuttle is retracted.

[0007] Typically, a conveyor system includes a conveyor belt that is shaped as a trough during operation. When the trough-shaped conveyor belt is guided through a height change, such as at a transition portion of a shuttle conveyor, the conveyor belt forms convex and concave curves. Maintaining the conveyor belt in a trough shape through a vertical curve of height change subjects the conveyor belt to stress. When the conveyor belt undergoes height changes, the stress may cause the conveyor belt to form a relatively complex curved shape. For example, the conveyor belt may form a dog-leg shape (when viewed from the side) in at least a portion of the height change.

[0008] In some cases, when formed to form a groove, the radius of the vertical curve of the conveyor belt can be significantly less than the recommended minimum operating radius of the conveyor belt at the height change. This may cause the conveyor belt to experience overstress, buckling and / or other irreversible bending at its edges, resulting in damage to the conveyor belt. Such overstress at the edges of the conveyor belt may be significantly higher than the allowable belt stress limit, resulting in damage, such as the conveyor belt breaking at its edges. Damage caused by the stress imposed on the conveyor belt may require the conveyor belt to be repaired or replaced at a higher frequency than a conveyor belt not subjected to similar stresses.

[0009] Constraints of a conveyor system that affect the distance over which changes in height of a conveyor belt may occur may be difficult or impossible to accommodate while maintaining the desired functionality of the conveyor system. For example, a conveyor system may need to convey material over a certain distance through a path limited by one or more constraints, such as the material properties of the conveyor belt, the positioning and size of idlers, and the motion requirements of certain system components, such as the shuttle of a shuttle conveyor system.

[0010] Therefore, providing a conveyor system that reduces conveyor belt damage while still meeting related operating requirements (i.e., conveying material through height changes by guiding a trough-shaped conveyor belt) can provide significant improvements to the operating efficiency and production costs of a production facility.

[0011] The problem of overstressing conveyor belts that are shaped into grooves through height changes is a long-standing problem in the conveyor industry. This can be addressed, at least to some extent, by one or more of the following: reducing the groove angle of the conveyor belt at the height change and increasing the rating of the conveyor belt. However, reducing the groove angle may result in increased material spillage, and higher rated conveyor belts are generally heavier (requiring more energy to drive the conveyor system) and more expensive to manufacture, purchase and / or install.

[0012] It should be understood that, if any prior art publication is referenced herein, such reference does not constitute an admission that the publication forms part of the common general knowledge in the art, in Australia or any other country.

[0013] SUMMARY OF THE DISCLOSURE

[0014] A conveyor system is provided that supports a conveyor belt in a trough shape through a transition section where the height of the conveyor belt changes.

[0015] The transition portion may include an upward change in altitude followed by a downward change in altitude.

[0016] The downward altitude change can be greater than the upward altitude change.

[0017] The upward change in altitude can be greater than the downward change in altitude.

[0018] The conveyor belt may be directed through a number of vertical curves at the transition section.

[0019] The radius of curvature of one or more of the vertical curves may be greater than a threshold radius.

[0020] At the upward change in elevation, the conveyor belt may be directed through a first upward concave vertical curve and a first downward concave vertical curve.

[0021] The conveyor belt may be directed through a second concave vertical curve at the downward change in elevation.

[0022] The conveyor system may include: a plurality of trough rollers; and a support structure to which the plurality of trough rollers are mounted.

[0023] Trough idlers may be configured to support the conveyor belt in a trough shape.

[0024] The plurality of grooved rollers may include a first plurality of intermediate grooved rollers, the first plurality of intermediate grooved rollers including: a first subset of grooved rollers, the first subset of grooved rollers forming a first upper concave roller path; and a second subset of grooved rollers, the second subset of grooved rollers forming a first lower concave roller path.

[0025] The first concave upward roller path may define a first radius of curvature that is greater than a first threshold radius.

[0026] The first concave roller path may define a second radius of curvature that is greater than a second threshold radius.

[0027] The first upper concave idler path and the first lower concave idler path may form a continuous ascending idler path.

[0028] The plurality of troughing rollers may include: a second plurality of intermediate troughing rollers; and an end troughing roller.

[0029] The second plurality of intermediate troughing rollers and the end troughing rollers may form a second concave roller path.

[0030] The radius of curvature of the second concave roller path may be greater than the third threshold radius.

[0031] The ascending idler path and the second concave idler path may be continuous.

[0032] The support structure may include: an upright roller support structure; and a suspended roller support structure.

[0033] The first plurality of intermediate troughing idlers may include a plurality of standing idlers mounted to the standing idler support structure.

[0034] The second plurality of intermediate troughing rollers may include a plurality of suspension rollers mounted to the suspension roller support structure.

[0035] The conveyor system may further include a shuttle. The shuttle may include: a plurality of shuttle rollers configured to support the conveyor belt; and a head pulley.

[0036] The shuttle may be configured to move between an extended position and a retracted position in which one or more shuttle idlers are retracted below the transition portion.

[0037] The conveyor system may further include a shuttle drive system operably connected to the shuttle, the shuttle drive system operable to move the shuttle between the extended position and the retracted position.

[0038] Movement of the shuttle from the extended position to the retracted position may cause at least one of the plurality of shuttle trough rollers to pass beneath one of the second plurality of intermediate trough rollers.

[0039] A conveyor system is provided that supports a conveyor belt in a trough shape through a transition section where the height of the conveyor belt changes.

[0040] The transition portion may include a downward change in altitude followed by an upward change in altitude.

[0041] The upward change in altitude can be greater than the downward change in altitude.

[0042] The conveyor belt may be directed through several vertical curves at the transition section.

[0043] The radius of curvature of one or more of the vertical curves may be greater than a threshold radius.

[0044] A conveyor belt redirection system is provided. The conveyor belt redirection system may include: a plurality of trough rollers supporting the conveyor belt; and a support structure supporting the plurality of trough rollers. The plurality of trough rollers may include: a starting trough roller supported at a starting height relative to a reference plane; an end trough roller supported at an end height relative to the reference plane; a first plurality of intermediate trough rollers supported along a first longitudinal length of the conveyor belt redirection system, each successive trough roller in the first plurality of intermediate trough rollers being supported at a height higher than a previous trough roller in the first plurality of intermediate trough rollers relative to the reference plane; and a second plurality of intermediate trough rollers supported along a second longitudinal length of the conveyor belt redirection system, the second longitudinal length being between an end of the first longitudinal length and the end trough roller, each successive trough roller in the second plurality of intermediate trough rollers being supported at a height lower than a previous trough roller in the second plurality of intermediate trough rollers relative to the reference plane.

[0045] A conveyor belt redirection system is provided. The conveyor belt redirection system may include: a plurality of trough rollers configured to support a conveyor belt. The plurality of trough rollers may include: a starting trough roller; a first plurality of intermediate trough rollers; a second plurality of intermediate trough rollers; and an end trough roller. The plurality of trough rollers may include a support structure configured to: support the starting trough roller at a starting height relative to a reference plane; support the end trough roller at an end height relative to the reference plane; support the first plurality of intermediate trough rollers at continuously increasing heights greater than the starting height relative to the reference plane along a first longitudinal length of the conveyor belt redirection system; and support the second plurality of intermediate trough rollers at continuously decreasing heights greater than the end height relative to the reference plane along a second longitudinal length of the conveyor belt redirection system, the second longitudinal length being between an end of the first longitudinal length and the end trough roller.

[0046] The first plurality of intermediate troughing rollers may include a first subset of troughing rollers forming a first concave upward roller path.

[0047] The first concave upward roller path may define a first radius of curvature that is greater than a first threshold radius.

[0048] The first plurality of intermediate troughing rollers may include a second subset of troughing rollers forming a first concave roller path.

[0049] The first concave roller path may define a second radius of curvature that is greater than a second threshold radius.

[0050] The first upper concave idler path and the first lower concave idler path may form a continuous ascending idler path.

[0051] The raised idler path may extend from a first height relative to the reference plane that is equal to or greater than the starting height to a peak height relative to the reference plane that is greater than the starting height.

[0052] The second plurality of intermediate troughing rollers and the end troughing rollers may form a second concave roller path.

[0053] The radius of curvature of the second concave roller path may be greater than the third threshold radius.

[0054] The third threshold radius may be equal to the second threshold radius.

[0055] The second concave idler path can extend from a second peak height relative to the reference plane to a descending height relative to the reference plane that is less than the second peak height.

[0056] The peak height and the second peak height may be equal.

[0057] The ascending idler path and the second concave idler path may be continuous.

[0058] The plurality of troughing rollers may include a third plurality of intermediate troughing rollers supported along an intermediate longitudinal length of the conveyor belt redirection system, the intermediate longitudinal length being located between an end of the first longitudinal length and an end of the second longitudinal length.

[0059] One or more of the third plurality of intermediate trough rollers may be supported by the support structure at a greater height relative to the reference plane than a previous trough roller in the third plurality of intermediate trough rollers.

[0060] One or more of the third plurality of intermediate troughing rollers may be supported by the support structure at a common height relative to the reference plane as a preceding troughing roller of the third plurality of intermediate troughing rollers.

[0061] One or more of the third plurality of intermediate trough rollers may be supported by the support structure at a lower height relative to the reference plane than a previous trough roller in the third plurality of intermediate trough rollers.

[0062] The plurality of troughing rollers may include a third plurality of intermediate troughing rollers.

[0063] The support structure can be configured to support one or more of the third plurality of intermediate trough rollers at a higher height relative to the reference plane than a previous trough roller of the third plurality of intermediate trough rollers along a middle longitudinal length of the conveyor belt redirection system, the middle longitudinal length being between an end of the first longitudinal length and an end of the second longitudinal length.

[0064] The support structure can be configured to support one or more of the third plurality of intermediate trough rollers at a common height relative to the reference plane as a previous trough roller of the third plurality of intermediate trough rollers along a middle longitudinal length of the conveyor belt redirection system, the middle longitudinal length being between an end of the first longitudinal length and an end of the second longitudinal length.

[0065] The support structure can be configured to support one or more of the third plurality of intermediate trough rollers at a lower height relative to the reference plane than a previous trough roller of the third plurality of intermediate trough rollers along a middle longitudinal length of the conveyor belt redirection system, the middle longitudinal length being between an end of the first longitudinal length and an end of the second longitudinal length.

[0066] The first plurality of intermediate troughing rollers may include a plurality of upright rollers configured to be mounted to an upright roller support structure.

[0067] The second plurality of intermediate troughing rollers may include a plurality of suspension rollers configured to be mounted to the suspension roller support structure.

[0068] The plurality of trough rollers may be configured to support the conveyor belt so that the conveyor belt forms: a trough for holding material; an upper concave portion, the upper concave portion being at least partially supported by some of the first plurality of intermediate trough rollers; and a lower concave portion, the lower concave portion extending from an end of the upper concave portion and being supported by several of the first plurality of intermediate trough rollers and several of the second plurality of intermediate trough rollers.

[0069] The conveyor belt redirection system may further include a shuttle. The shuttle may include: a shuttle body; a plurality of shuttle trough rollers mounted to the shuttle body; and a head roller mounted to the shuttle body.

[0070] The shuttle may be configured to move between an extended position and a retracted position, in which the head roller is closer to the start trough roller than when the shuttle is in the extended position.

[0071] In each of the extended position and the retracted position, one or more of the plurality of shuttling trough rollers can be at a height relative to a reference plane that is less than a height of each of the second plurality of trough rollers.

[0072] Movement of the shuttle from the extended position to the retracted position may cause at least one of the plurality of shuttle trough rollers to pass beneath one of the second plurality of intermediate trough rollers.

[0073] The conveyor belt redirection system may further include a shuttle drive system configured to be connected to the shuttle. The shuttle drive system may be operable to move the shuttle between the extended position and the retracted position.

[0074] The support structure may include: a starting trough roller mounting portion, to which a starting trough roller can be mounted; an end trough roller mounting portion, to which an end trough roller can be mounted; a first plurality of intermediate trough roller mounting portions, wherein the first plurality of intermediate trough roller mounting portions are positioned at continuously increasing heights relative to a reference plane along a first longitudinal length of the conveyor belt redirection system, and each of the first plurality of intermediate trough rollers can be mounted to a corresponding one of the first plurality of intermediate trough roller mounting portions; and a second plurality of intermediate trough roller mounting portions, wherein the second plurality of intermediate trough roller mounting portions are positioned at continuously decreasing heights relative to the reference plane along a second longitudinal length of the conveyor belt redirection system, and each of the second plurality of intermediate trough rollers can be mounted to a corresponding one of the second plurality of intermediate trough roller mounting portions.

[0075] A support structure is provided. The support structure may include: a starting trough roller mounting portion configured to enable the starting trough roller to be mounted at a starting height relative to a reference plane; a terminal trough roller mounting portion configured to enable the terminal trough roller to be mounted at a terminal height relative to the reference plane; a first plurality of intermediate trough roller mounting portions positioned along a first longitudinal length of the support structure, the first plurality of intermediate trough roller mounting portions configured to enable the first plurality of intermediate trough rollers to be positioned at continuously increasing heights relative to the reference plane that are greater than the starting height; and a second plurality of intermediate trough roller mounting portions positioned along a second longitudinal length of the support structure, the second plurality of intermediate trough roller mounting portions configured to enable the second plurality of intermediate trough rollers to be positioned at continuously decreasing heights relative to the reference plane that are greater than the terminal height, the second longitudinal length being between an end of the first longitudinal length and the terminal trough roller.

[0076] When constructing the support structure, the initial troughed roller mounting portion may be positioned relative to the reference plane at the initial troughed roller mounting portion height.

[0077] When constructing the support structure, the end trough roller mounting portion may be positioned at the end trough roller mounting portion height relative to the reference plane.

[0078] When constructing the support structure, the first plurality of intermediate troughed roller mounting portions may be positioned at successively increasing heights relative to the reference plane that are greater than the starting troughed roller mounting portion height.

[0079] When constructing the support structure, the second plurality of intermediate troughed roller mounting portions may be positioned at successively lower heights relative to the reference plane that are greater than the end troughed roller mounting portion heights.

[0080] When constructing the support structure, a first subset of the first plurality of intermediate trough-shaped idler mounting portions can define a first upper concave mounting portion path.

[0081] The first concave mounting portion path may have a first radius of curvature greater than a first threshold radius.

[0082] When constructing the support structure, a second subset of the first plurality of intermediate trough-shaped idler mounting portions can define a first recessed mounting portion path.

[0083] The first concave mounting portion path may define a second radius of curvature greater than a second threshold radius.

[0084] The first upward concave mounting portion path and the first downward concave mounting portion path may form an ascending mounting portion path.

[0085] The ascending mounting portion path may extend from a first mounting portion height relative to the reference plane that is equal to or greater than the starting height to a peak mounting portion height relative to the reference plane that is greater than the starting height.

[0086] When the support structure is constructed, the second plurality of intermediate trough-shaped idler mounting portions may form a second concave mounting portion path.

[0087] The second concave mounting portion path may define a third radius of curvature greater than a third threshold radius.

[0088] The third threshold radius may be equal to the second threshold radius.

[0089] The second recessed mounting portion path may extend from a second peak mounting portion height relative to the reference plane to a dropped mounting portion height relative to the reference plane, the dropped mounting portion height being less than the second peak mounting portion height.

[0090] The peak mounting portion height and the second peak mounting portion height may be equal.

[0091] The first recessed mounting portion path and the second recessed mounting portion path may be continuous.

[0092] The support structure may also include a third plurality of intermediate trough shaped roller mounting portions positioned along an intermediate longitudinal length of the support structure between ends of the first longitudinal length and ends of the second longitudinal length.

[0093] The third plurality of intermediate trough roller mounting portions can be configured to enable one or more of the third plurality of intermediate trough rollers to be supported at a higher height relative to a reference plane than a previous trough roller of the third plurality of intermediate trough rollers.

[0094] The third plurality of intermediate trough roller mounting portions can be configured such that one or more of the third plurality of intermediate trough rollers can be supported at a common height relative to a reference plane as a previous trough roller of the third plurality of intermediate trough rollers.

[0095] The third plurality of intermediate trough roller mounting portions can be configured to enable one or more of the third plurality of intermediate trough rollers to be supported at a lower height relative to a reference plane than a previous trough roller of the third plurality of intermediate trough rollers.

[0096] The support structure may also include a shuttle support portion, which is configured to support the shuttle: when the shuttle is in an extended position; when the shuttle is in a retracted position, wherein the nose roller of the shuttle is closer to the starting grooved roller mounting portion than when the shuttle is in the extended position; and when the shuttle moves between the extended position and the retracted position.

[0097] A conveyor belt redirection system is provided. The conveyor belt redirection system may include: a support structure as described herein; and a plurality of trough rollers, the plurality of trough rollers including: a starting trough roller; an end trough roller; a first plurality of intermediate trough rollers; and a second plurality of intermediate trough rollers.

[0098] The conveyor belt redirection system may also include a third plurality of intermediate troughed idlers.

[0099] The support structure may also include an upright roller support structure.

[0100] The first plurality of troughing rollers may include a plurality of upright rollers configured to be mounted to an upright roller support structure.

[0101] The support structure may also include a suspension roller support structure.

[0102] The second plurality of troughing rollers may include a plurality of suspension rollers configured to be mounted to the suspension roller support structure.

[0103] The plurality of trough rollers may be configured to support the conveyor belt so that the conveyor belt forms: a trough for holding material; an upper concave portion at least partially supported by one or more of the first plurality of intermediate trough rollers; and a lower concave portion supported by several of the first plurality of intermediate trough rollers and several of the second plurality of intermediate trough rollers.

[0104] A conveyor system is provided. The conveyor system may include the conveyor belt redirection system described herein. The conveyor system may include the support structure described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0106] Embodiments of the present invention are further described below by way of example only with reference to the accompanying drawings, in which:

[0107] Figure 1 is a schematic diagram of the conveyor system;

[0108] Figure 2 is a schematic diagram of a conveyor system according to some embodiments;

[0109] Figure 3 The use of some embodiments is shown Figure 2 A perspective view of a conveyor system shown in a schematic representation in FIG. 1 , showing a portion of a conveyor belt redirection system of the conveyor system, and schematically representing a portion of the conveyor system;

[0110] Figure 4 According to some embodiments Figure 3 A perspective view of a portion of a conveyor system;

[0111] Figure 5 According to some embodiments Figure 3 A perspective view of a portion of a conveyor system, wherein a frame of the conveyor system is hidden;

[0112] Figure 6 According to some embodiments Figure 3 A front view of a portion of a conveyor system;

[0113] Figure 7 According to some embodiments Figure 3 A front view of a portion of a conveyor system, wherein a frame of the conveyor system is hidden;

[0114] Figure 8 shows a perspective view of a trough roller according to some embodiments;

[0115] Fig. 9 shows a perspective view of another trough idler according to some embodiments;

[0116] Fig.10According to some embodiments Figure 3 a side view of a portion of a conveyor system;

[0117] Fig.11 According to some embodiments Figure 3 a side view of a portion of a conveyor system;

[0118] Fig.12 According to some embodiments Figure 3 a side view of a portion of a conveyor system, wherein a frame of the conveyor system is concealed;

[0119] Fig.13 According to some embodiments Figure 3 a side view of a portion of a conveyor system, wherein a frame of the conveyor system is concealed;

[0120] Fig.14 According to some embodiments Figure 3 a plan view of a sagittal cross-section of a portion of a conveyor system, wherein a frame of the conveyor system is concealed;

[0121] Fig.15 According to some embodiments Figure 3 another plan view of a sagittal cross-section of a portion of a conveyor system, wherein a frame of the conveyor system is concealed;

[0122] Fig.16 According to some embodiments Figure 3 another plan view of a sagittal cross-section of a portion of a conveyor system, wherein a frame of the conveyor system is concealed;

[0123] Fig.17 According to some embodiments Figure 3 a plan view of a sagittal cross-section of a portion of a conveyor system;

[0124] Fig.18 According to some embodiments Figure 3 another plan view of a sagittal cross-section of a portion of the conveyor system;

[0125] Fig.19 shows a schematic diagram of a conveyor system according to some embodiments;

[0126] Fig. 20 shows a schematic diagram of a conveyor system according to some embodiments; and

[0127] Fig.21 A schematic diagram of a conveyor system is shown according to some embodiments.

[0128] Description of Embodiments

[0129] Overview of conveyor systems including belt height changes

[0130] Figure 1 is a schematic diagram of an exemplary conveyor system 2. The conveyor system 2 is a shuttle conveyor system that shapes the conveyor belt 4 into a trough to assist in conveying material. The material may be loose mined material. The conveyor belt 4 is arranged to form a closed endless conveyor belt loop 6. Idlers (not shown) and rollers are used to guide the conveyor belt 4 through the conveyor belt loop 6. The conveyor system 2 includes a height change 50 of the conveyor belt 4.

[0131] The conveyor belt 4 is driven by a drive roller 10 in a drive direction 8. Upstream and downstream position references can be made with reference to the drive direction 8 at specific points of the conveyor belt loop 6. The drive roller 10 engages with the conveyor belt 4 so that rotation of the drive roller 10 causes corresponding movement of the conveyor belt 4. The conveyor system 2 includes a head roller 12 and a tail roller 14. The conveyor system 2 includes a tensioning roller 16. The tensioning roller 16 is used to ensure that the tension in the conveyor belt 4 is maintained within an appropriate operating range. The conveyor system 2 includes a first bend pulley 18, a second bend pulley 20, and a third bend pulley 22. As the conveyor belt 4 is driven through the conveyor belt loop 6 in the drive direction 8, the rollers of the conveyor system 2 redirect the conveyor belt 4.

[0132] The conveyor system 2 comprises a loading system 24. The material to be conveyed by the conveyor system 2 is loaded onto the conveyor belt 4 via the loading system 24.

[0133] The conveyor system 2 includes a shuttle 32. The head roller 12 is mounted to the shuttle 32. The shuttle 32 can be in an extended position 34 (e.g. Figure 1 ) and the retracted position 36 (as shown Figure 1 The control of the position of the shuttle 32 enables the material conveyed by the conveyor system 2 to be transported to several different end positions (eg, into different chutes).

[0134] Similar to Figure 1 The conveyor system of the conveyor system may include sections where the conveyor belt is supported at different heights by associated conveyor belt loops. Figure 1The upper surface of a portion 33 of the conveyor belt 4 supported by the shuttle 32 is at a lower height 42 that is lower than the upper height 40 of the upper surface of a portion 35 of the conveyor belt 4 supported by the conveyor system 2 upstream of the shuttle 32. Therefore, the conveyor system 2 includes a transition portion 38 in which the conveyor belt 4 transitions from the upper height 40 to the lower height 42. In other words, the conveyor belt 4 is guided through a height change 50 at the transition portion 38. The upper height 40 and the lower height 42 are measured in a height direction 44 (e.g., in a direction perpendicular to a ground surface 46) relative to a common reference.

[0135] The conveyor belt 2 is shaped to be grooved by grooved rollers toward the tail end 26 upstream of the loading system 24. The conveyor belt 2 remains grooved through a transition portion 38 until the conveyor belt approaches the head roller 12 toward the head end 30 of the conveyor system 2.

[0136] Conveyor systems including height changes

[0137] Problems with conveyor systems that include height changes

[0138] As described herein, conveyor systems may be subject to various constraints that affect, to some extent, the profile of the conveyor system and / or the conveyor belt loop of the associated conveyor system. Thus, some conveyor systems may include height changes through which the conveyor belt of the conveyor system is guided.

[0139] For example, in the case where the altitude change is a decrease in altitude, e.g. Figure 1 In the transition portion 38 of the conveyor system 2, the conveyor belt is guided through a concave downward curve of a specific radius, followed by a concave upward curve of another radius to accommodate the height change.

[0140] Throughout this description, it will be understood that a curve may be referred to as concave if the concavity of the curve is downward. In other words, a curve may be referred to as a concave curve if it has a generally concave profile relative to an observation point below the curve (i.e., at a height less than the height of the component forming the curve). In some embodiments, such a curve may be referred to as a convex curve. For example, a concave curve may be considered to be a convex curve relative to an observation point above the curve.

[0141] Throughout this description, it will be understood that a curve may be referred to as being concave-upward if the concavity of the curve is directed upward. In other words, a curve may be referred to as being concave-upward if it has a generally concave profile relative to an observation point above the curve (i.e., at a height greater than the height of the components forming the curve). In some embodiments, such a curve may be referred to as a convex curve. For example, a concave-upward curve may be considered to be a convex curve relative to an observation point below the curve.

[0142] Maintaining the conveyor belt in a trough shape through vertical curves of varying heights subjects the conveyor belt to stresses which cause the conveyor belt to form relatively complex curved shapes as it traverses the height changes.

[0143] Throughout this description, it should be understood that a vertical curve can be considered to be a curve that involves a change in height in a vertical direction along the length of the curve. That is, a vertical curve can be considered to be a curve that involves a change in height relative to a direction perpendicular to a reference plane (e.g., a direction perpendicular to a plane parallel to a ground surface). For example, in the case where a conveyor belt is formed as a curve with a height at one end that is higher than the height at the other end, the conveyor belt can be said to form a vertical curve. Similarly, in the case where a conveyor belt is formed as a curve with a height at one end that is lower than the height at the other end, the conveyor belt can be said to form a vertical curve.

[0144] When a trough-shaped belt is guided through a vertical curve, it is forced to temporarily bend outward at its edges. That is, the conveyor belt is forced to bend outward from the trough-shaped shape into which it is biased. Gravity, the weight of the conveyor belt, and the weight of the material carried by the conveyor belt oppose the outward bending. However, belt bending and associated deformation of the conveyor belt can cause the edges of the conveyor belt to stretch beyond acceptable limits (e.g., rated edge tension). This can cause the conveyor belt to experience overstress, buckling, and / or other irreversible bending at its edges, resulting in damage to the conveyor belt.

[0145] It should be noted that since the conveyor belt is flattened out of the groove before passing over the head rollers, edge tension like this is not normally applied to the belt as it passes over the rollers.

[0146] Reduce the stress on the conveyor belt by changing the height

[0147] The conveyor system described herein can significantly reduce the stress imposed on the conveyor belt when the conveyor belt is shaped as a trough and is guided through a height change during operation. The conveyor system supports the conveyor belt into a trough shape through a transition portion. The height of the conveyor belt is changed by the transition portion. Specifically, the transition portion includes an upward height change and a subsequent downward height change.

[0148] The described conveyor system includes a conveyor belt redirection system that redirects the conveyor belt of the conveyor system in a direction opposite to a desired elevation change before directing the conveyor belt through the desired elevation change. By doing so, the radius of one or more vertical curves through which the conveyor belt is directed is increased. When formed into the trough, one or more of these radii can be increased to or above a threshold radius of the conveyor belt, thereby reducing edge tension of the conveyor belt as the conveyor belt passes through the elevation change.

[0149] The conveyor belt loop of the described conveyor system includes a reduction in height. The conveyor belt redirection system directs the conveyor belt through an initial increase in height before directing the conveyor belt through the reduction in height. The net change in height is the same as if the conveyor belt redirection system were omitted; however, the radius of one or more vertical curves through which the conveyor belt is directed is greater than the radius through which the conveyor belt would be directed without the disclosed conveyor belt redirection system. Thus, for a given grade of conveyor belt, edge tension of the conveyor belt can be reduced as the conveyor belt changes height during operation, and the operating life of the conveyor belt can be increased.

[0150] While the constraint of needing to vary the height of the conveyor system is at least in part a result of accommodating the movement of the shuttle, it should be appreciated that the conveyor belt redirection system can also reduce stresses placed on the conveyor belt when used in other situations unrelated to shuttle conveyors that involve variations in the height of the conveyor belt as it is formed into a trough.

[0151] Furthermore, while the conveyor belt redirection system is described in the context of facilitating a reduction in height of a conveyor belt loop, it should be understood that a similar conveyor belt redirection system may be used to facilitate an increase in height of a conveyor belt loop of an alternative conveyor system. Such a conveyor belt redirection system may first direct the conveyor belt through an initial decrease in height before directing the conveyor belt through an increase in height. Again, the net change in height may be the same as if the conveyor belt redirection system were omitted; however, the radii of the vertical curves through which the conveyor belt will be directed will be greater than those radii through which the conveyor belt will be directed without the conveyor belt redirection system.

[0152] Overview of Conveyor System 100

[0153] Figure 2 is a schematic diagram of a conveyor system 100 according to some embodiments. Figures 3 to 18 Several views of the conveyor system 100 and / or one or more portions of the conveyor system 100 are shown.

[0154] The conveyor system 100 is configured to convey material. The material may be loose mined material. The conveyor system 100 extends in a conveyor system longitudinal direction 109. The conveyor system 100 extends from a tail end 110 to a head end 114. The conveyor system 100 extends from a tail end 110 to a head end 114 in the conveyor system longitudinal direction 109. The conveyor system 100 defines a conveyor system longitudinal axis 101. The conveyor system longitudinal axis 101 is parallel to the conveyor system longitudinal direction 109. The conveyor system longitudinal axis 101 is shown to be straight.

[0155] It should be understood that if the conveyor system 100 is to bend along its length, the conveyor system longitudinal direction 109 can be defined as being curved along its length to be parallel to the sagittal plane of the conveyor system 100. Similarly, in such an embodiment, the conveyor system longitudinal axis 101 can be curved along its length to be generally parallel to the sagittal plane of the conveyor system 100.

[0156] The conveyor system 100 includes a conveyor belt 102 . Figure 2 A schematic diagram of the conveyor belt 102 is shown in FIG. Figures 3 to 5 A perspective view of a first portion 102A of the conveyor belt 102 is shown. A second portion 102B of the conveyor belt 102 is shown. Figures 3 to 5 and Figures 10 to 13 The conveyor belts 102 are arranged to form a closed endless conveyor belt loop 103. The conveyor belts 102 circulate through the conveyor belt loop 103 as described herein.

[0157] The conveyor belt 102 includes a skeleton 111 (see Figure 3 ). The skeleton 111 includes an outer covering. The outer covering includes a polymer. For example, the outer covering may include rubber. The outer covering defines an outer conveyor belt surface. The conveyor belt 102 includes an inner covering. The inner covering includes a polymer. For example, the inner covering may include rubber. The inner covering defines an inner conveyor belt surface. It should be understood that the outer covering and the outer conveyor belt surface may be referred to as a top covering and a top conveyor belt surface, respectively. Similarly, it should be understood that the inner covering and the inner conveyor belt surface may be referred to as a bottom covering and a bottom conveyor belt surface, respectively. The conveyor belt 102 includes a core. The skeleton 111 may be referred to as including a core. The core is disposed between the outer covering and the inner covering. The conveyor belt 102 includes a first lateral edge portion defining a first lateral edge and an opposite second lateral edge portion defining a second lateral edge. The skeleton 111 may be referred to as including a first lateral edge portion and a second lateral edge portion.

[0158] The conveyor belt 102 has several conveyor belt characteristics. The conveyor belt 102 may be selected to suit a particular production process based on the conveyor belt characteristics of the conveyor belt 102. The conveyor belt characteristics include one or more of a distance between an outer conveyor belt surface and an inner conveyor belt surface (this distance may be referred to as the thickness of the conveyor belt 102), a distance between a first lateral edge and a second lateral edge (this distance may be referred to as the width of the conveyor belt 102), a thickness of an outer cover, a thickness of an inner cover, a material of an outer cover, a material of an inner cover, a surface finish of an outer cover, a size of a core, and a material of a core.

[0159] In some embodiments, the width of the conveyor belt 102 can be about 1.8m. In some embodiments, the width of the conveyor belt 102 can be 1m, 1.1m, 1.2m, 1.3m, 1.4m, 1.5m, 1.6m, 1.7m, 1.8m, 1.9m, 2.0m, 2.1m, 2.2m, 2.3m, 2.4m, 2.5m or 3m. In some embodiments, the width of the conveyor belt 102 can be between 1m and 3m. In some embodiments, the thickness of the outer covering can be about 15mm. In some embodiments, the thickness of the outer covering can be 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm or 20mm. In some embodiments, the thickness of the outer covering can be between 10mm and 20mm. In some embodiments, the thickness of the inner covering can be about 5mm. In some embodiments, the thickness of the inner covering can be about 6mm. In some embodiments, the thickness of the inner covering can be 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm or 10mm. In some embodiments, the thickness of the inner covering is between 3mm and 10mm.

[0160] One or more conveyor belt characteristics of a conveyor belt are affected by the operational requirements of the particular production process in which the conveyor belt is used. For example, if the conveyor belt is to be used under particularly tough conditions, the thickness of a particular conveyor belt may need to be relatively large to increase the life of the conveyor belt during operation. This may be a particularly important issue when the conveyor belt is supported in a trough shape as described herein. When a trough-shaped conveyor belt is driven through one or more radii of curvature, the edge tension of the conveyor belt at this area may increase. In the case where the radius of curvature is small enough (i.e., equal to or below a threshold radius), the edge tension may exceed an edge tension threshold, thereby causing damage to the conveyor belt.

[0161] If a conveyor belt having appropriate conveyor belt characteristics (e.g., a thickness that accommodates the greater stress associated with the radius of curvature) is not selected, the conveyor belt may fail prematurely. However, selecting the appropriate conveyor belt may result in other disadvantages. For example, a conveyor belt having a greater thickness may have a greater mass. Therefore, the energy requirements of the associated conveyor system may be greater than the original energy requirements when a conveyor belt having a smaller thickness can be used. The conveyor system 100 described herein can reduce the stress applied to the conveyor belt 102 during use. This can increase the operating life of the conveyor belt 102 without changing one or more conveyor belt characteristics, such as the thickness of the conveyor belt 102 (which may have a deleterious effect on the conveyor system 100 (e.g., increased power consumption)).

[0162] The conveyor system 100 includes a conveyor system frame 104. The conveyor system frame 104 may be referred to as a frame of the conveyor system 100. The conveyor system frame 104 is configured to support several components of the conveyor system 100, as described herein. Several components of the conveyor system frame 104 are hidden in the figure.

[0163] The conveyor system 100 includes a loading system 105. Material to be conveyed by the conveyor system 100 is loaded onto the conveyor belt 102 via the loading system 105. The loading system 105 controls the rate at which the material is loaded onto the conveyor belt 102. The loading system 105 can control the rate at which the material is loaded onto the conveyor belt 102 based on one or more of the mass of the material, the bulk density of the material, and the speed of the conveyor belt 102. The loading system 105 is positioned at the tail end 110 of the conveyor system 100.

[0164] The conveyor system 100 includes a drive roller 106. The drive roller 106 is schematically shown in Figures 2 to 5 and Figures 10 to 13 . The drive roller 106 is configured to rotate about a drive roller axis. The drive roller axis is orthogonal to the conveyor system longitudinal axis 101. The drive roller axis is orthogonal to the vertical axis.

[0165] The conveyor system 100 includes a drive system (not shown). The drive system is supported by the conveyor system frame 104. The drive system is connected to the drive roller 106. The drive system is operable to rotate the drive roller 106 around the drive roller axis in a rotation direction. In other words, the drive system is operable to rotate the drive roller 106 along the rotation direction. The rotation direction can be clockwise. The rotation direction can be counterclockwise. In certain embodiments, the drive system is operable to rotate the drive roller 106 around the drive roller axis in both clockwise and counterclockwise directions.

[0166] The drive roller 106 is configured to engage the conveyor belt 102. In particular, the drive roller 106 engages the inner conveyor belt surface. In the illustrated embodiment, the drive roller 106 frictionally engages the conveyor belt 102 such that rotation of the drive roller 106 causes corresponding movement of the conveyor belt 102. The drive roller 106 rotates in a rotational direction to move the conveyor belt 102 in a drive direction 107. It should be appreciated that in some embodiments, the drive roller 106 may engage the conveyor belt 102 in another manner. For example, the drive roller 106 may include teeth and the conveyor belt 102 include corresponding internal grooves.

[0167] The conveyor system 100 includes a tail roller 108. A schematic representation of the tail roller 108 is shown in FIG. Figure 2 and Figure 31. The tail roller 108 is supported by the conveyor system frame 104. The tail roller 108 is positioned at the tail end 110 of the conveyor system 100. The tail roller 108 is configured to rotate about a tail roller axis. The tail roller axis is parallel to the drive roller axis. The tail roller 108 is configured to support the conveyor belt 102 and rotate about the tail roller axis when the conveyor belt 102 is driven through the conveyor belt loop 103.

[0168] The conveyor system 100 includes a head roller 112. The head roller 112 is schematically shown in Figure 2 and Figure 3 1. The head roller 112 is disposed at the head end 114 of the conveyor system 100. The head roller 112 is configured to rotate around the head roller axis. The head roller axis is parallel to the drive roller axis. The head roller 112 is configured to support the conveyor belt 102 and rotate around the head roller axis when the conveyor belt 102 is driven through the conveyor belt loop 103.

[0169] The conveyor system 100 includes a tensioning roller 116. A schematic representation of the tensioning roller 116 is shown in FIG. Figures 2 to 5 and Figures 10 to 13 1. The tensioning roller 116 is configured to rotate about a tensioning roller axis. The tensioning roller axis is parallel to the drive roller axis. The tensioning roller 116 is configured to move to control the belt tension of the conveyor belt 102 during operation. The tensioning roller 116 can be downward (i.e., toward the ground surface 118, such as Figure 2 The tension roller 116 can be moved upward (ie, away from the ground surface 118) to reduce the belt tension of the conveyor belt 102.

[0170] The conveyor system 100 includes a plurality of redirecting rollers. In particular, the conveyor system 100 includes a first redirecting roller 120. The first redirecting roller 120 is configured to change the moving direction of the conveyor belt 102 when the conveyor belt 102 passes through the first redirecting roller 120. The conveyor system 100 includes a second redirecting roller 122. The second redirecting roller 122 is configured to change the moving direction of the conveyor belt 102 when the conveyor belt 102 passes through the second redirecting roller 122. The conveyor system 100 includes a third redirecting roller 124. The third redirecting roller 124 is configured to change the moving direction of the conveyor belt 102 when the conveyor belt 102 passes through the third redirecting roller 124.

[0171] The conveyor system 100 includes a transition section 145. The conveyor system 100 supports the conveyor belt 102 into a trough shape through the transition section 145. The height of the conveyor belt 102 changes through the transition section 145. The transition section 145 includes an upward height change. In other words, there is an upward height change of the conveyor belt 102 at the transition section 145. The transition section 145 includes a subsequent downward height change. In other words, there is a downward height change of the conveyor belt 102 at the transition section. The downward height change is downstream of the upward height change. The downward height change is greater than the upward height change. Therefore, the conveyor belt 102 is supported at a lower height than the upstream of the transition section 145 downstream of the transition section 145. The conveyor belt 102 is guided through several vertical curves 178 at the transition section 145, as described herein. In some embodiments, the vertical curves 178 of the conveyor belt 102 and / or one or more other components of the conveyor system can be considered to include curves that are vertically aligned between positions. For example, the alignment of the conveyor belt 102 may curve in a vertical plane as it passes through the length of the conveyor system 100. Such a curve may be referred to as a vertical curve. The vertical curve may include an upward concave curve. The vertical curve may include a downward concave curve.

[0172] Roller 130

[0173] The conveyor system 100 includes a plurality of rollers 130. Several rollers in the plurality of rollers 130 are Figures 3 to 5 and Figures 10 to 15 Specifically, a plurality of rollers 130 are Figures 3 to 5 and Figures 10 to 13 In the figure, they are schematically represented as crosses. Figures 3 to 18 A perspective view of several of the plurality of rollers 130 is shown. Some of the rollers 130 are mounted to the conveyor system frame 104. The rollers 130 support the conveyor belt 102. In particular, the rollers 130 support the conveyor belt 102 between the tail roller 108 and the head roller 112 as the conveyor belt 102 passes through the conveyor belt loop 103. Several of the rollers 130 that support the conveyor belt 102 as the conveyor belt 102 conveys material are trough rollers. The trough rollers hold the conveyor belt 102 so that the conveyor belt 102 forms a trough 119 (see FIG. 1 ) as it passes through the associated trough rollers. Figure 6 ). The plurality of rollers 130 supporting the conveyor belt 102 may be flat rollers.

[0174] The conveyor system 100 includes a plurality of support rollers 131. The support rollers 131 are arranged on a Figures 3 to 5 and Figures 10 to 131. Some of the support rollers 131 are mounted to the conveyor system frame 104. The support rollers 131 are configured to support the conveyor belt 102 as the conveyor belt 102 returns from the head roller 112 to the tail roller 108. The conveyor belt 102 is unloaded while being supported by the support rollers 131. In other words, the support rollers support the conveyor belt 102 when the conveyor belt 102 is not loaded with material.

[0175] As described herein, the number of rollers 130 that support the conveyor belt 102 as it is driven from the tail drum 108 to the head drum 112 are trough rollers. Figure 8 A perspective view of one of the trough rollers 130 is shown. Figure 8 The trough roller 130 is in the form of an upright roller. The upright roller is configured to be supported by a support structure disposed below the upright roller.

[0176] Trough roller 130 includes trough roller frame 127. Trough roller frame 127 may be referred to as an upright roller frame. Trough roller frame 127 includes frame base 129. Frame base 129 may be referred to as an upright roller base. Frame base 129 is configured to be mounted to an associated support structure. Trough roller frame 127 includes a plurality of roller support portions 133. Roller support portions 133 are connected to frame base 129 and extend away from frame base 129. In some embodiments, roller support portions 133 are integrally formed with frame base 129.

[0177] The trough roller 130 includes a center roller 135. The trough roller frame 127 is configured to support the center roller 135. The center roller 135 is cylindrical. The center roller 135 is configured to rotate about a center roller axis (not shown) when supported by the trough roller frame 127.

[0178] The trough roller 130 includes a pair of opposing angled rollers 146, 147. In particular, the trough roller 130 includes a first angled roller 146 and a second angled roller 147. The first angled roller 146 is supported at a first end of the center roller 135 by a corresponding roller support portion 133. The first angled roller 146 is cylindrical. The first angled roller 146 is configured to rotate about a first angled roller axis (not shown) when supported by the trough roller 130. The first angled roller axis is transverse to the center roller axis. The second angled roller 147 is supported at a second end of the center roller 135 by a corresponding roller support portion 133. The second angled roller 147 is cylindrical. The second angled roller 147 is configured to rotate about a second angled roller axis (not shown) when supported by the trough roller 130. The second angled roller axis is transverse to the center roller axis. Roller support portion 133 is configured to support the ends of respective rollers such that rollers 135, 146, 147 define a groove 148. When conveyor belt 102 is supported by grooved idler rollers 130, conveyor belt 102 forms groove 119, as described herein.

[0179] Fig. 9 A perspective view of another trough-shaped idler 130 among the plurality of idlers 130 is shown. Fig. 9 The grooved roller 130 is in the form of a suspension roller. The suspension roller is configured to be supported by a support structure arranged above the suspension roller.

[0180] Fig. 9 The trough roller 130 includes a trough roller frame 153. The trough roller frame 153 may be referred to as a hanging roller frame. The trough roller frame 153 includes a frame base 155. The frame base 155 may be referred to as a hanging roller base. The frame base 155 is configured to be mounted to an associated support structure. The trough roller frame 153 includes a plurality of roller support portions 157. The roller support portions 157 are connected to the frame base 155. In some embodiments, the roller support portions 157 are integrally formed with the frame base 155.

[0181] Fig. 9 The trough roller 130 includes a center roller 159. The trough roller frame 153 is configured to support the center roller 159. The center roller 159 is cylindrical. The center roller 159 is configured to rotate around a center roller axis (not shown) when supported by the trough roller frame 153.

[0182] Fig. 9The trough roller 130 includes a pair of opposing angled rollers 163, 165. In particular, the trough roller 130 includes a first angled roller 163 and a second angled roller 165. The first angled roller 163 is supported at a first end of the center roller 159. The first angled roller 163 is cylindrical. The first angled roller 163 is configured to rotate around a first angled roller axis (not shown) when supported by the trough roller 130. The first angled roller axis is transverse to the center roller axis. The second angled roller 165 is supported at a second end of the center roller 159. The second angled roller 165 is cylindrical. The second angled roller 165 is configured to rotate around a second angled roller axis (not shown) when supported by the trough roller 130. The second angled roller axis is transverse to the center roller axis. The roller support portion 157 is configured to support the ends of the respective rollers so that the rollers 159, 163, 165 define a trough 167. When the conveyor belt 102 is Fig. 9 The conveyor belt 102 forms a groove 119 when supported by the grooved rollers 130 as described herein.

[0183] In some embodiments, when one of the plurality of rollers 130 is described herein as a trough roller, it may be referred to as a Figure 8 The grooved roller 130 described or referenced Fig. 9 The form of the grooved roller 130 described. That is, the roller 130 can be an upright roller or a hanging roller.

[0184] When one of the plurality of rollers 130 is described herein as being supported at a particular height, it is understood that the corresponding roller 130 is supported by the frame 104 or a portion thereof, and that the height is relative to (e.g., at Figure 2 and Fig.10 118 and a reference portion of the corresponding idler 130. The height corresponds to the distance between the reference plane 186 and the reference portion of the corresponding idler 130 measured in a direction orthogonal to the reference plane 186. This direction may be referred to as the height direction 188. In some embodiments, the reference plane 186 is tangent to a portion of the ground surface 118. The reference plane 186 may be substantially parallel to the ground surface 118. In some embodiments, the reference plane 186 is parallel to the linear belt path 152 of the conveyor system 100. In some embodiments, the reference portion of the corresponding idler 130 may correspond to the center point of the center roller of the idler 130. The center point may be located on the center roller axis at a point equidistant from each lateral end of the center roller. In some embodiments, the reference portion of the corresponding idler 130 may correspond to the point at which the idler 130 is mounted to the frame 104.

[0185] Where the heights of different idlers 130 are compared herein, it will be understood that the respective heights are determined based on the distances between the reference plane 186 and the corresponding reference portions of the different idlers 130. For example, the height of one of the idlers 130 is equal to the distance between the reference plane 186 and the reference portion of the idler 130 (e.g., the center point of the center roller of the trough idler 130) measured in the height direction 188. Similarly, the height of another of the idlers 130 is equal to the distance between the reference plane 186 and the reference portion of the idler 130 (e.g., the center point of the center roller of the trough idler 130) measured in the height direction 188.

[0186] Conveyor system 100 includes a plurality of roller mounting portions 175. In particular, frame 104 includes a plurality of roller mounting portions 175. Each roller mounting portion 175 is configured to support one roller 130 of a plurality of rollers 130. That is, one roller 130 of a plurality of rollers 130 may be mounted to a corresponding roller mounting portion 175. When frame 104 is constructed, each roller mounting portion 175 may be referred to as being positioned at a corresponding height. In addition, each roller mounting portion 175 is configured to support a corresponding roller 130 at a specific height.

[0187] Each of the plurality of roller mounting portions 175 can be associated with a corresponding reference portion. The reference portion can be associated with a portion of the corresponding roller mounting portion 175 that is directly related to the mounting of the corresponding roller 130. For example, in an embodiment where roller 130 is mounted to the associated roller mounting portion 175 via one or more bolted engagements, the reference portion of roller mounting portion 175 can be associated with a portion of roller mounting portion 175 that facilitates one of the bolted engagements (e.g., the reference portion can be a center point of a hole of roller mounting portion 175 that receives a bolt).

[0188] When one of the plurality of roller mounting portions 175 is described herein as being positioned at a particular height, it should be understood that the height is measured relative to reference plane 186 and the reference portion of the corresponding roller mounting portion 175. The height corresponds to the distance between reference plane 186 and the reference portion of the corresponding roller mounting portion 175 measured in height direction 188.

[0189] Where the heights of different roller mounting portions 175 are compared herein, it will be understood that the respective heights are determined based on the distances between the reference plane 186 and the corresponding reference portions of the different roller mounting portions 175. For example, the height of one of the roller mounting portions 175 is equal to the distance between the reference plane 186 and the reference portion of the roller mounting portion 175 measured in the height direction 188. Similarly, the height of another of the rollers 130 is equal to the distance between the reference plane 186 and the reference portion of the roller mounting portion 175 measured in the height direction 188.

[0190] Shuttle 126

[0191] The conveyor system 100 includes a shuttle 126. The shuttle 126 is Figure 2 , Fig.14 and Fig.16 Schematically shown in FIG. Shuttle 126 is supported by conveyor system frame 104. Shuttle 126 is configured to move along shuttle axis 128. Shuttle axis 128 is parallel to conveyor system longitudinal axis 101. Shuttle 126 includes shuttle body 132. Shuttle body 132 is disposed at Figure 2 , Fig.14 and Fig.16 The shuttle body 132 extends from a first shuttle body end portion 134 to a second shuttle body end portion 136.

[0192] The head roller 112 is mounted to the shuttle 126. In particular, the head roller 112 is mounted to the shuttle body 132 at a first shuttle body end portion 134. The first redirecting roller 120 is mounted to the shuttle 126. In particular, the first redirecting roller 120 is mounted to the shuttle body 132 at a second shuttle body end portion 136. The first redirecting roller 120 is mounted to the underside of the shuttle body 132.

[0193] The shuttle 126 includes a subset of the rollers 130 of the conveyor system 100. These rollers 130 may be referred to as shuttle rollers 138. In other words, the shuttle 126 includes a plurality of shuttle rollers 138. The plurality of shuttle rollers 138 are configured to support the conveyor belt 102 as it conveys material.

[0194] Several shuttle rollers 138 are Figures 3 to 5 A three-dimensional representation of several shuttle rollers 138 is shown schematically as a cross member. Figures 3 to 7 and Figures 10 to 18 The shuttle roller 138 is mounted to the shuttle body 132. The plurality of roller mounting portions 175 include a plurality of shuttle roller mounting portions 137 (see Figure 5 , Fig.17 ). The shuttle body 132 includes a plurality of shuttle roller mounting portions 137. The shuttle rollers 138 are configured to be mounted to the shuttle roller mounting portions 137. The shuttle roller mounting portions 137 are positioned between the first shuttle body end portion 134 and the second shuttle body end portion 136.

[0195] When mounted to the shuttle roller mounting portion 137, the shuttle rollers 138 are spaced apart along the shuttle body 132 between the first shuttle body end portion 134 and the second shuttle body end portion 136. One or more of the shuttle rollers 138 are spaced apart from adjacent shuttle rollers 138 by a shuttle roller spacing 139. The shuttle roller spacing 139 is associated with the spacing between the shuttle roller mounting portions 137.

[0196] In some embodiments, each shuttle roller 138 in the plurality of shuttle rollers 138 is separated from adjacent shuttle rollers 138 by the same distance. In other words, the shuttle roller spacing 139 of each shuttle roller 138 is the same. In some embodiments, one or more shuttle roller spacings 139 are about 3 m. The shuttle rollers 138 are configured to support the conveyor belt 102 when loaded with material.

[0197] The plurality of shuttle rollers 138 include a plurality of shuttle trough rollers 141. In other words, the shuttle trough rollers 141 are a subset of the shuttle rollers 138. The shuttle trough rollers 141 are configured to support the conveyor belt 102 when loaded with material. The shuttle trough rollers 141 are trough rollers mounted to the shuttle body 132. The shuttle trough rollers 141 can be connected to the reference Figure 8 The grooved roller 130 described or referenced Fig. 9 The trough rollers 130 described are similar or identical.

[0198] The plurality of shuttle rollers 138 include a plurality of flat shuttle rollers 143. The flat shuttle rollers 143 are Figure 3 The flat shuttle idlers 143 are mounted to the shuttle body 132 between the shuttle grooved idlers 141 and the head roller 112. The flat shuttle idlers 143 are configured to support the conveyor belt 102 when loaded with material.

[0199] The shuttle 126 includes a shuttle movement system (not shown). The shuttle movement system enables the shuttle to move along the shuttle axis 128. The shuttle movement system may include one or more of wheels, supports, and tracks.

[0200] The conveyor system 100 includes a shuttle drive system (not shown). The shuttle drive system is connected to the shuttle 126. The shuttle drive system is operable to cause movement of the shuttle 126. In particular, the shuttle drive system is operable to move the shuttle 126 between an extended position 140 and a retracted position 142. In other words, the shuttle 126 is configured to move between the extended position 140 and the retracted position 142. The shuttle 126 is controllably movable between a number of intermediate shuttle positions, which are located between the extended position 140 and the retracted position 142.

[0201] The conveyor system frame 104 is configured to support the shuttle 126. The conveyor system frame 104 includes a shuttle support portion (hidden in the drawings). The shuttle support portion is configured to support the shuttle 126 when the shuttle 126 is in the extended position 140. The shuttle support portion is configured to support the shuttle 126 when the shuttle 126 is in the retracted position 142. The shuttle support portion is configured to support the shuttle 126 when the shuttle is in the intermediate shuttling position. In other words, the shuttle support portion is configured to support the shuttle 126 when the shuttle 126 moves between the extended position 140 and the retracted position 142.

[0202] Head roller 112 Figure 2 and Figure 3 Schematically represented in . Figures 3 to 5 Also shown are a core drum intermediate position schematic representation 113 and a core drum retracted position schematic representation 115. The core drum intermediate position schematic representation 113 shows an exemplary position of the core drum 112 when the shuttle 126 is in the intermediate shuttle position. The core drum retracted position schematic representation 115 shows an exemplary position of the core drum 112 when the shuttle 126 is in the retracted position 142. When the shuttle 126 is in the intermediate shuttle position, the core drum 112 is closer to the tail drum 108 than when the shuttle 126 is in the extended position 140. When the shuttle 126 is in the retracted position 142, the core drum 112 is closer to the tail drum 108 than when the shuttle 126 is in the extended position 140 and when the shuttle 126 is in the intermediate position.

[0203] Figures 3 to 5 A first redirecting roller intermediate position schematic representation 121 and a first redirecting roller retracted position schematic representation 123 are shown. The first redirecting roller intermediate position schematic representation 121 shows an exemplary position of the first redirecting roller 120 when the shuttle 126 is in the intermediate shuttle position. The first redirecting roller retracted position schematic representation 123 shows an exemplary position of the first redirecting roller 120 when the shuttle 126 is in the retracted position 142.

[0204] Conveyor belt loop 103

[0205] The conveyor belt loop 103 may be described with reference to the path that a reference portion of the conveyor belt 102 travels during operation of the conveyor system 100. The reference portion 144 of the conveyor belt 102 may be considered to begin the conveyor belt loop 103 near the tail drum 110 but downstream of the tail drum 110 and upstream of the loading system 105. The drive drum 106 is driven by the drive system to move the conveyor belt 102 in the drive direction 107 to complete the conveyor belt loop 103. The reference portion 144 is supported by the described drums and plurality of idlers 130 as the reference portion 144 is driven through the conveyor belt loop 103.

[0206] The reference portion 144 moves along the conveyor belt loop 103 from the tail roller 108. As the reference portion 144 moves away from the tail roller 108 toward the loading system 105, the rollers 130 supporting the conveyor belt 102 transition from flat rollers to grooved rollers. The reference portion 144 moves toward the loading system 105, and as the conveyor belt 102 passes through the loading system 105, material is loaded onto the conveyor belt 102. The reference portion 144 moves until the reference portion 144 meets the head roller 112. That is, the reference portion 144 moves away from the tail roller 108 toward the head roller 112. As the reference portion 144 is driven from the tail roller 108 toward the head roller 112, the reference portion 144 is guided through the linear belt path 152 and the serpentine belt path 154. As the reference portion 144 is driven from the tail roller 108 to the head roller 112, the reference portion 144 is supported by a plurality of rollers 130. These rollers 130 may be positioned to control the profile of the conveyor belt 102 as described herein.

[0207] The direction of movement of the reference portion 144 changes at the head roller 112. The reference portion 144 passes the head roller 112 and then moves away from the head roller 112 and toward the first redirecting roller 120 (and also toward the tail roller 108) as the conveyor belt 102 moves further through the conveyor belt loop 103.

[0208] The direction of movement of the reference portion 144 changes at the first bend roller 120. The reference portion 144 passes the first bend roller 120 and then moves away from the first bend roller 120 toward the drive roller 106 (and also toward the head roller 112) as the conveyor belt 102 moves further through the conveyor belt loop 103.

[0209] The direction of movement of the reference portion 144 changes at the drive roller 106. The reference portion 144 passes the drive roller 106 and then moves away from the drive roller 106 toward the second redirecting roller 122 as the conveyor belt 102 moves further through the conveyor belt loop 103.

[0210] The direction of movement of the reference portion 144 changes at the second bend roller 122. The reference portion 144 passes the second bend roller 122 and then moves away from the second bend roller 122 toward the tension roller 116 as the conveyor belt 102 moves further through the conveyor belt loop 103. The reference portion 144 moves downward toward the tension roller 116.

[0211] The direction of movement of the reference portion 144 changes at the tensioning roller 116. The reference portion 144 passes the tensioning roller 116 and then moves away from the tensioning roller 116 toward the third redirecting roller 124 as the conveyor belt 102 moves further through the conveyor belt loop 103. The reference portion 144 moves upward toward the third redirecting roller 124.

[0212] The direction of movement of the reference portion 144 changes at the third bend roller 124. The reference portion 144 passes the third bend roller 124 and then moves toward the tail roller 108 to complete the conveyor loop 103 as the conveyor belt 102 moves further through the conveyor loop 103.

[0213] Install Partial Path

[0214] The installation portion path may be defined by connecting the reference portions of several roller installation portions 175 with one or more virtual lines. In particular, the installation portion path may be defined by connecting the reference portions of several roller installation portions 175 with a curve. The curve may have a continuous gradient. The curve may be represented by a spline curve. Fig.17 and Fig.18 Several example installation partial paths 226, 232, 244 are shown.

[0215] A portion of a mounting portion path may be referred to as being concave-up if the concavity of the mounting portion path is directed upward. That is, if the portion of the mounting portion path forms a generally concave profile with respect to an observation point above the portion of the mounting portion path (i.e., at a height greater than the height of one or more of the associated roller mounting portions 175). Where the portion of the mounting portion path is defined by a curve, the portion may be referred to as being concave-up if the gradient of the portion (determined with reference to an appropriate coordinate system) increases along the length of the portion.

[0216] A portion of a mounting portion path may be referred to as concave if the concavity of the mounting portion path is downward. That is, if the portion of the mounting portion path forms a generally concave profile with respect to an observation point below the portion of the mounting portion path (i.e., at a height less than the height of the associated idler mounting portion 175). Where the portion of the mounting portion path is defined by a curve, the portion may be referred to as concave if the gradient of the portion (determined with reference to an appropriate coordinate system) decreases along the length of the portion.

[0217] For purposes of this description, the installation portion path is considered to extend in the conveyor system longitudinal direction 109 , with the gradient being determined with reference to an x-axis extending in the conveyor system longitudinal direction 109 and a y-axis extending in the height 188 .

[0218] Roller path

[0219] The roller path may be defined by connecting reference portions of several rollers 130 with one or more virtual lines. In particular, the roller path may be defined by connecting reference portions of several rollers 130 with a curve. The curve may have a continuous gradient. The curve may be represented by a spline curve. Fig.17 and Fig.18 Several example roller paths 250 , 258 , 266 are shown in FIG.

[0220] A portion of a roller path may be referred to as concave-up if the concavity of the roller path is directed upward. That is, if the portion of the roller path forms a generally concave profile with respect to an observation point above the portion of the roller path (i.e., at a height greater than the height of one or more of the associated rollers 130). Where the portion of the roller path is defined by a curve, the portion may be referred to as concave-up if the gradient of the portion (determined with reference to an appropriate coordinate system) increases along the length of the portion.

[0221] A portion of a roller path may be referred to as concave if the concavity of the roller path is downward. That is, if the portion of the roller path forms a generally concave profile with respect to an observation point below the portion of the roller path (i.e., at a height less than the height of the associated roller 130). Where the portion of the roller path is defined by a curve, the portion may be referred to as concave if the gradient of the portion (determined with reference to an appropriate coordinate system) decreases along the length of the portion.

[0222] For purposes of this description, the roller path is considered to extend in the conveyor system longitudinal direction 109 , with the slope being determined with reference to an x-axis extending in the conveyor system longitudinal direction 109 and a y-axis extending at height 188 .

[0223] Conveyor Belt Redirection System 150

[0224] Figure 2 The conveyor system 100 is Figure 1 A variation of the conveyor system 2 of the present disclosure is provided that incorporates a conveyor belt redirection system 150 of the present disclosure. That is, the conveyor system 100 includes the conveyor belt redirection system 150. The conveyor belt redirection system 150 redirects the conveyor belt 102 first upwardly and then downwardly before the conveyor belt 102 is conveyed to the shuttle idlers 138. In this manner, the radius of one or more of the vertical curves 178 through which the conveyor belt 102 is directed is increased as compared to the radius of one or more of the vertical curves 178 through which the conveyor belt 102 would be directed without the conveyor belt redirection system 150. As a result, during operation, when the conveyor belt 102 moves onto the shuttle 126 (i.e., when the conveyor belt 102 is directed through a height change), the edge tension of the conveyor belt 102 can be reduced, and the operating life of the conveyor belt 102 can be improved.

[0225] An example of an increase in the radius of one of the vertical curves 178 through which the conveyor belt is guided is shown in FIG. Figure 1 and Figure 2 Shown in. Figure 1 The radius of curvature 197 of the vertical curve 178 is shown, Figure 1 The conveyor belt 4 of the conveyor system 2 is guided through the vertical curve 178 . Figure 2 The radius of curvature 199 of the vertical curve 178 is shown, Figure 2 The conveyor belt 102 of the conveyor system 100 is guided through the vertical curve 178. Figure 1 and Figure 2 As can be seen in Figure 2 The curvature radius 199 of the conveyor belt 102 is greater than Figure 1 The radius of curvature 197 of the conveyor belt 4. This larger radius of curvature is at least partially achieved by the conveyor belt redirection system 150 described herein.

[0226] Several parts of the conveyor belt redirection system 150 are Figures 3 to 18 A portion of the conveyor belt redirection system 150 is shown in Figures 3 to 5 , to help ensure clear representation of several components of the conveyor belt redirection system 150. Figure 3 and Figure 4 , the conveyor belt redirection system 150 is shown supporting the first portion 102A of the conveyor belt 102 .

[0227] refer to Figure 2 and Figure 3, the conveyor belt redirection system 150 is configured to redirect the conveyor belt 102 from a linear belt path 152 through a serpentine belt path 154. The linear belt path 152 is a path having a generally linear profile. In other words, the gradient of the linear belt path 152 can be constant or can be within a specific range around a constant gradient. The serpentine belt path 154 is a path having a generally curved profile. In other words, the gradient of the serpentine belt path 154 varies along the length of the serpentine belt path 154.

[0228] Support structure 151

[0229] refer to Figure 3 , Figure 4 , Figure 6 and Figure 7 , the conveyor belt redirection system 150 includes a support structure 151. The support structure 151 is configured to support one or more portions of the conveyor system 100. Specifically, the support structure 151 supports several of the plurality of rollers 130 such that the rollers 130 support the conveyor belt 102 through a path having an initial height increase and a subsequent height decrease before the conveyor belt 102 is moved onto the shuttle 126. The support structure can be referred to as a frame. The support structure 151 can be referred to as a conveyor belt redirection system frame. The support structure 151 includes support members 170. The support members 170 are configured to be assembled to form a load-bearing structure 172 of the support structure 151. The load-bearing structure 172 is configured to support the support structure 151 and / or one or more other components in the conveyor system 100.

[0230] Support structure 151 includes an upright roller support structure 174. Upright roller support structure 174 may be mounted to load bearing structure 172. Upright roller support structure 174 supports one or more other components of conveyor system 100, as described herein.

[0231] The support structure 151 includes a suspension roller support structure 176. The suspension roller support structure 176 may be mounted to the load bearing structure 172. The suspension roller support structure 176 supports one or more other components of the conveyor system 100, as described herein.

[0232] Support structure 151 is configured to support shuttle 126. In some embodiments, support structure 151 includes a shuttle support portion as described herein.

[0233] Roller 156 of conveyor belt redirection system 150

[0234] The conveyor belt redirection system 150 includes a plurality of rollers 156 ( Figure 3 and Fig.14102). The idlers 156 of the conveyor belt redirection system 150 are a subset of the plurality of idlers 130 of the conveyor system 100. In other words, the plurality of idlers 130 of the conveyor system 100 include the plurality of idlers 156 of the conveyor belt redirection system 150. The plurality of idlers 156 include a plurality of trough idlers 158. In other words, the conveyor belt redirection system 150 includes a plurality of trough idlers 158. The trough idlers 158 are configured to support the conveyor belt 102. The plurality of idlers 156 include shuttle idlers 138.

[0235] One or more of the grooved rollers 158 may be used in conjunction with the grooved rollers 158 of the present invention. Figure 8 The grooved rollers 130 described above are similar or identical to those in the embodiment of the present invention. One or more of the grooved rollers 158 may be the same as those in the embodiment of the present invention. Fig. 9 The trough rollers 130 described are similar or identical.

[0236] The plurality of trough rollers 158 includes a plurality of upright rollers 169. The upright rollers 169 are connected to an upright roller support structure 174. The plurality of trough rollers 158 includes a plurality of suspension rollers 171. The suspension rollers 171 are connected to a suspension roller support structure 176.

[0237] Multiple grooved rollers 158

[0238] Figures 3 to 7 and Figures 10 to 18 A view of several portions of a conveyor belt redirection system 150 as it is constructed is shown. A portion of the conveyor belt redirection system 150 is hidden in the figure. As described herein, the conveyor belt redirection system 150 includes a plurality of trough rollers 158. An upstream portion of a support structure 151 supporting the plurality of trough rollers 158 is hidden in the figure. Similarly, a downstream portion of the support structure 151 supporting the plurality of trough rollers 158 is hidden in the figure.

[0239] refer to Figure 3 , Figure 5 and Fig.10 , support structure 151 includes a plurality of roller mounting portions 175. Plurality of roller mounting portions 175 includes a plurality of trough roller mounting portions 181. In other words, trough roller mounting portions 181 are a subset of roller mounting portions 175. Trough roller mounting portions 181 are configured to support trough rollers 158. In other words, trough roller mounting portions 181 are a portion of support structure 151 to which one of trough rollers 158 may be mounted. In some embodiments, each of roller mounting portions 175 of conveyor belt redirection system 150 is in the form of a trough roller mounting portion 181.

[0240] refer to Figures 14 to 16, multiple trough rollers 158 include a starting trough roller 180. Multiple trough roller mounting portions 181 include a starting trough roller mounting portion 182. In other words, support structure 151 includes starting trough roller mounting portion 182. Starting trough roller 180 can be mounted to starting trough roller mounting portion 182. For example, starting trough roller 180 can be mounted to starting trough roller mounting portion 182 using bolted joints.

[0241] When constructing the conveyor belt redirection system 150, it can be said that the starting trough roller mounting portion 182 is set at the starting trough roller mounting portion height 183 (at Fig.11 When constructing the conveyor belt redirection system 150, it can be said that the starting trough roller 180 is supported at a starting height 184 ( Fig.11 In other words, the starting trough roller mounting portion 182 is configured to enable the starting trough roller 180 to be installed at the starting height 184.

[0242] Reference again Figures 14 to 16 , the plurality of trough rollers 158 include an end trough roller 190. The plurality of trough roller mounting portions 181 include an end trough roller mounting portion 192. In other words, the support structure 151 includes an end trough roller mounting portion 192. The end trough roller 190 may be mounted to the end trough roller mounting portion 192. For example, the end trough roller 190 may be mounted to the end trough roller mounting portion 192 using a bolted joint.

[0243] When the conveyor belt redirection system 150 is configured, the end trough roller 190 is located downstream of the start trough roller 180. In other words, the end trough roller 190 is closer to the head drum 112 than the start trough roller 180. When the conveyor belt redirection system 150 is configured, the end trough roller mounting portion 192 is located downstream of the start trough roller mounting portion 182. In other words, the end trough roller mounting portion 192 is closer to the head drum 112 than the start trough roller mounting portion 182.

[0244] When constructing the conveyor belt redirection system 150, it can be said that the end trough roller mounting portion 192 is disposed at the end trough roller mounting portion height 185 (at Fig.13 When constructing the conveyor belt redirection system 150, it can be said that the end trough roller 190 is supported at the end height 194 ( Fig.13 In other words, the end trough roller mounting portion 192 is configured to enable the end trough roller 190 to be mounted at the end height 194.

[0245] refer to Figure 2 and Figures 14 to 16, the conveyor system 100 includes a transition section 145. The transition section 145 is a portion of the conveyor system 100 where the height of the conveyor belt 102 changes while the conveyor belt 102 maintains a trough shape. The transition section 145 extends between a starting point 193 and an end point 195. The starting point 193 can be considered a first end of the transition section 145. The end point 195 can be considered a second end of the transition section 145. The conveyor belt 102 is guided through a number of vertical curves 178 between the starting point 193 and the end point 195 of the transition section 145. The conveyor belt support system 150 defines at least a portion of the transition section 145. The length of the conveyor belt 102 across the transition section 145 at a particular time can be referred to as the transition length.

[0246] In some embodiments, the transition portion 145 can be considered to extend from the starting trough roller 180 to one of the shuttle rollers 138. The associated shuttle roller 138 can be the shuttle roller 138 at which the conveyor belt 102 transitions from having a curved longitudinal profile to a linear longitudinal profile. In some embodiments, the transition portion 145 can be considered to extend from near the starting trough roller 180 to near the associated shuttle roller 138. For example, the transition portion can be considered to extend from the midpoint between the starting trough roller 180 and the immediately upstream roller 130 to the midpoint between the associated shuttle roller 138 and the immediately downstream shuttle roller 138.

[0247] The first plurality of intermediate grooved rollers 196

[0248] The plurality of grooved rollers 158 include a first plurality of intermediate grooved rollers 196. The first plurality of intermediate grooved rollers 196 are Fig.10 , Fig.14 and Fig.15 In some embodiments, the first plurality of intermediate trough rollers 196 includes a specific number of trough rollers 196. The number of trough rollers 196 in the first plurality of intermediate trough rollers 196 can be a number greater than or equal to 1. In the illustrated embodiment, the first plurality of intermediate trough rollers 196 includes 13 trough rollers 196.

[0249] The plurality of trough roller mounting portions 181 includes a first plurality of intermediate trough roller mounting portions 198. The support structure 151 includes a first plurality of intermediate trough roller mounting portions 198. The upright roller support structure 174 includes a plurality of intermediate trough roller mounting portions of the first plurality of intermediate trough roller mounting portions 198. The suspension roller support structure 176 includes a plurality of intermediate trough roller mounting portions of the first plurality of intermediate trough roller mounting portions 198. A plurality of intermediate trough rollers of the first plurality of intermediate trough rollers 196 are upright rollers. These trough rollers 196 may be mounted to the upright roller support structure 174. A plurality of intermediate trough rollers of the first plurality of intermediate trough rollers 196 are suspension rollers. These trough rollers 196 may be mounted to the suspension roller support structure 176.

[0250] One or more trough rollers 196 in the first plurality of intermediate trough rollers 196 may be mounted to corresponding roller mounting portions 198 in the first plurality of intermediate trough roller mounting portions 198. One or more trough rollers 196 in the first plurality of intermediate trough rollers 196 may be mounted to corresponding roller mounting portions 198 in the first plurality of intermediate trough roller mounting portions 198 using bolted engagement.

[0251] refer to Fig.11 In configuring conveyor belt redirection system 150, it can be said that each of first plurality of intermediate trough rollers 196 is supported at a corresponding first intermediate trough roller height 202. In other words, roller mounting portion 198 is configured to enable trough rollers 196 to be mounted at a corresponding first intermediate trough roller height 202. First intermediate trough roller height 202 is greater than or equal to starting height 184. In some embodiments, one or more of first intermediate trough roller heights 202 can be less than starting height 184.

[0252] When configuring conveyor belt redirection system 150, it can be said that each trough roller mounting section 198 of first plurality of intermediate trough roller mounting sections 198 is supported at a corresponding first intermediate trough roller mounting section height 208. First intermediate trough roller mounting section height 208 is greater than or equal to starting height 184.

[0253] First plurality of intermediate trough shaped idler mounting portions 198 includes a particular number of roller mounting portions 198. The number of roller mounting portions 198 can be a number greater than or equal to 1. In the illustrated embodiment, first plurality of intermediate trough shaped idler mounting portions 198 includes 13 roller mounting portions 198. In some embodiments, first plurality of intermediate trough shaped idler mounting portions 198 includes the same number of roller mounting portions 198 as first plurality of intermediate trough shaped idler rollers 196 includes trough shaped idler rollers 196. In some embodiments, first plurality of intermediate trough shaped idler mounting portions 198 includes a different number of roller mounting portions 198 than first plurality of intermediate trough shaped idler rollers 196 includes trough shaped idler rollers 196. For example, in some embodiments, first plurality of intermediate trough shaped idler mounting portions 198 includes a greater number of roller mounting portions 198 than first plurality of intermediate trough shaped idler rollers 196 includes trough shaped idler rollers 196.

[0254] refer to Fig.12 , the first plurality of intermediate trough roller mounting portions 198 are positioned along a first longitudinal length 200 of the conveyor system 100. The first longitudinal length 200 extends parallel to the conveyor longitudinal axis 101. The first longitudinal length 200 is located downstream of the starting trough roller 180 in the conveyor system longitudinal direction 109. The first longitudinal length 200 can be referred to as a first longitudinal length of the support structure 151. The first longitudinal length 200 can be referred to as a first longitudinal length of the conveyor belt redirection system 150. Therefore, when the first plurality of intermediate trough rollers 196 are mounted to the first plurality of intermediate trough roller mounting portions 198, the first plurality of intermediate trough rollers 198 can be referred to as being positioned along the first longitudinal length 200 of the conveyor belt redirection system 150.

[0255] When configuring conveyor belt redirection system 150, first plurality of intermediate troughed idler mounting sections 198 are positioned at continuously increasing heights 208 as first longitudinal length 200 traverses from upstream end 206 to downstream end 208. In other words, first intermediate troughed idler mounting section heights 208 increase along first longitudinal length 200.

[0256] Thus, first plurality of intermediate trough roller mounting portions 198 are configured to enable first plurality of intermediate trough rollers 196 to be supported at continuously increasing heights 202 along first longitudinal length 200. In other words, first intermediate trough roller heights 202 increase along first longitudinal length 200 in conveyor system longitudinal direction 109. When conveyor belt redirection system 150 is configured, first plurality of intermediate trough rollers 196 are therefore supported at continuously increasing heights along first longitudinal length 200.

[0257] It should be appreciated that in some embodiments, one or more of roller mounting portions 198 of first plurality of intermediate trough shaped roller mounting portions 198 can be positioned at a common height relative to reference plane 146 as immediately preceding roller mounting portion 198. That is, while the height trend of first plurality of intermediate trough shaped roller mounting portions 198 along first longitudinal length 200 can be increasing in height, it should be appreciated that each roller mounting portion 198 of first plurality of intermediate trough shaped roller mounting portions 198 need not necessarily be located at a higher height than immediately preceding roller mounting portion 198.

[0258] It should also be appreciated that in some embodiments, one or more of the trough rollers 196 of the first plurality of intermediate trough rollers 196 may be positioned at a common height relative to the reference plane 146 as the immediately preceding trough roller 196. That is, while the height trend of the first plurality of intermediate trough rollers 196 along the first longitudinal length 200 may be increasing in height, it should be appreciated that each trough roller 196 of the first plurality of intermediate trough rollers 196 need not necessarily be at a greater height than the immediately preceding trough roller 196.

[0259] When the conveyor belt redirection system 150 is configured, the first plurality of intermediate trough roller mounting sections 198 are downstream of the initial trough roller mounting sections 182. In other words, the first plurality of intermediate trough roller mounting sections 198 are closer to the head roller 112 than the initial trough roller mounting sections 182. When the conveyor belt redirection system 150 is configured, the first plurality of intermediate trough rollers 196 are downstream of the initial trough rollers 180. In other words, the first plurality of intermediate trough rollers 196 are closer to the head roller 112 than the initial trough rollers 180.

[0260] When mounted to first plurality of intermediate trough roller mounting portions 198, first plurality of intermediate trough rollers 196 are spaced apart along support structure 151. Fig.10 , one or more of the first plurality of intermediate trough rollers 196 are separated from adjacent intermediate trough rollers 196 by a first spacing 189. First spacing 189 is a distance. The first spacing can be measured by connecting the associated intermediate trough rollers 196 with a straight line. First spacing 189 is associated with the spacing between the intermediate trough roller mounting portions 198. For example, in some embodiments, the associated intermediate trough roller mounting portions 198 are separated by the first spacing 189. Therefore, the corresponding intermediate trough rollers 196 can also be separated by a distance equal to the first spacing 189. Therefore, first spacing 189 can be measured by connecting the associated intermediate trough roller mounting portions 198 with a straight line.

[0261] In some embodiments, each intermediate trough roller mounting portion of the first plurality of intermediate trough roller mounting portions 198 is spaced apart from adjacent intermediate trough roller mounting portions 198 by the same distance. In some embodiments, each intermediate trough roller of the first plurality of intermediate trough rollers 196 is spaced apart from adjacent intermediate trough rollers 196 by the same distance. In some embodiments, the first spacing 189 is approximately 3 meters. In some embodiments, the first spacing 189 is 1 meter, 1.5 meters, 2 meters, 2.5 meters, 3 meters, 3.5 meters, 4 meters, 4.5 meters, 5 meters, or greater than 5 meters. In some embodiments, the first spacing 189 is between 1 meter and 10 meters or between 2 meters and 5 meters. In some embodiments, the first spacing 189 is proportional to the desired curvature of the conveyor belt 102.

[0262] First concave mounting portion path 226

[0263] refer to Fig.15 and Fig.17 , when constructing the support structure 151, the first subset 224 of the first plurality of intermediate trough-shaped roller mounting portions 198 defines an upward concave curve. That is, the first subset 224 of the first plurality of intermediate trough-shaped roller mounting portions 192 defines an upward concave mounting portion path 226. In particular, the curve connecting the corresponding reference points of each mounting portion 198 of the first subset 224 defines the upward concave mounting portion path 226. The upward concave mounting portion path 226 has an upward concave profile. The upward concave mounting portion path 226 has a continuous gradient. The upward concave mounting portion path 226 can be referred to as a first upward concave mounting portion path 226.

[0264] The gradient of the concave mounting portion path 226 increases along the length of the concave mounting portion path 226 in the conveyor system longitudinal direction 109. In other words, the gradient of the concave mounting portion path 226 increases as the concave mounting portion path 226 is traversed away from the starting trough roller mounting portion 182 in the conveyor system longitudinal direction 109. The concave mounting portion path 226 has a first radius of curvature 228. The first radius of curvature 228 is equal to or greater than a first threshold radius. The first threshold radius is the radius at which the edge tension of the conveyor belt 102 is below an edge tension threshold when the conveyor belt 102 is formed to form the trough 119. The edge tension threshold is a force. In some embodiments, the first threshold radius is approximately 263 meters. In some embodiments, the first threshold radius is approximately 100 meters, 200 meters, 220 meters, 240 meters, 260 meters, 280 meters, 300 meters, or 400 meters. In some embodiments, the first threshold radius is between 100 meters and 400 meters or between 200 meters and 300 meters. In some embodiments, the edge tension threshold force is about 421.2 kN. In some embodiments, the edge tension threshold force is about 200 kN, 250 kN, 300 kN, 350 kN, 400 kN, 450 kN, 500 kN, 550 kN, or 600 kN. In some embodiments, the edge tension threshold force is between 200 kN and 600 kN or between 400 kN and 500 kN.

[0265] First concave installation portion path 232

[0266] refer to Fig.16 and Fig.17 , when constructing support structure 151, second subset 230 of first plurality of intermediate trough shaped idler mounting portions 198 defines a concave curve. That is, second subset 230 of first plurality of intermediate trough shaped idler mounting portions 198 defines a concave mounting portion path 232. In particular, a curve connecting respective reference points of each mounting portion 198 of second subset 230 defines concave mounting portion path 232. Concave mounting portion path 232 has a concave profile. Concave mounting portion path 232 has a continuous gradient. Concave mounting portion path 232 may be referred to as a first concave mounting portion path.

[0267] The gradient of the concave mounting portion path 232 decreases along the length of the concave mounting portion path 232 in the conveyor system longitudinal direction 109. In other words, the gradient of the concave mounting portion path 232 decreases as the concave mounting portion path 232 is traversed away from the starting trough roller mounting portion 182 in the conveyor system longitudinal direction 109. The concave mounting portion path 232 has a second radius of curvature 234. The second radius of curvature 234 is equal to or greater than a second threshold radius. The second threshold radius is the radius at which the edge tension of the conveyor belt 102 is below a second edge tension threshold when the conveyor belt 102 is formed to form the trough 119. The second edge tension threshold is a force. The second edge tension threshold may be equal to the first edge tension threshold. The second threshold radius may be equal to the first threshold radius.

[0268] The upper concave mounting section path 226 and the lower concave mounting section path 232 form an ascending mounting section path. The ascending mounting section path extends from a first mounting section height 236 to a first peak mounting section height 238. The first mounting section height 236 is equal to or greater than the starting height 184. The first peak mounting section height 238 is greater than the starting height 184. The first peak mounting section height 238 is greater than the first mounting section height 236.

[0269] First concave roller path 250

[0270] refer to Fig.15 and Fig.17 , when the support structure 151 is constructed, the first plurality of intermediate trough roller mounting portions 198 support the first plurality of intermediate trough rollers 196. When mounted to the support structure 151, the first subset 251 of the first plurality of intermediate trough rollers 196 defines an upward concave curve. That is, the first subset 251 of the first plurality of intermediate trough rollers 196 defines an upward concave roller path 250. In particular, a curve connecting the corresponding reference points of each roller 196 of the first subset 251 defines the upward concave roller path 250. The upward concave roller path 250 has an upward concave profile. The upward concave roller path 250 has a continuous gradient. The upward concave roller path 250 can be referred to as a first upward concave roller path. When the conveyor belt 102 is driven across the first subset 251 of the first plurality of intermediate trough rollers 196, the conveyor belt 102 moves through a curved path corresponding to the upward concave roller path 250.

[0271] The gradient of the concave roller path 250 increases along the length of the concave roller path 250 in the longitudinal direction 109 of the conveyor system. In other words, the gradient of the concave roller path 250 increases as the concave roller path 250 is traversed away from the starting trough roller 180 in the longitudinal direction 109 of the conveyor system. The concave roller path 250 has a first radius of curvature 252. The first radius of curvature 252 is equal to or greater than a first threshold radius. The first threshold radius is the radius at which the edge tension of the conveyor belt 102 is below an edge tension threshold when the conveyor belt 102 is supported by the rollers 130 and is shaped to form the trough 119 at the concave roller path 250.

[0272] Since the first radius of curvature 252 is equal to or greater than the first threshold radius, the edge tension in the conveyor belt 102 will remain equal to or below the edge tension threshold when the conveyor belt 102 is guided through the concave path corresponding to the upper concave idler path 250. In the case where the edge tension threshold corresponds to a tension exceeding which damage to the conveyor belt 102 is caused, damage to the conveyor belt 102 can be reduced by guiding the conveyor belt 102 through the concave path.

[0273] First concave roller path 256

[0274] When the support structure 151 is constructed, the second subset 254 of the first plurality of intermediate trough rollers 196 defines a concave curve. That is, the second subset 254 of the first plurality of intermediate trough rollers 196 defines a concave roller path 256. In other words, when the first plurality of intermediate trough rollers 196 are supported by the first plurality of intermediate trough roller mounting portions 198, the first plurality of intermediate trough rollers 196 define a concave roller path 256. The concave roller path 256 may be referred to as a first concave roller path. A curve connecting the respective reference points of each roller 196 of the second subset 254 defines the concave roller path 256. The concave roller path 256 has a concave profile. The concave roller path 256 has a continuous gradient. When the conveyor belt 102 is driven across the second subset 254 of the first plurality of intermediate trough rollers 196, the conveyor belt 102 moves through a curved path corresponding to the concave roller path 256.

[0275] The gradient of the concave idler path 256 decreases along the length of the concave idler path 256 in the conveyor system longitudinal direction 109. In other words, the gradient of the concave idler path 256 decreases as the concave idler path 256 is traversed away from the starting trough-shaped idler mounting portion 182 in the conveyor system longitudinal direction 109. The concave idler path 256 has a second radius of curvature 258. The second radius of curvature 258 is equal to or greater than a second threshold radius. The second threshold radius is the radius at which the edge tension of the conveyor belt 102 is below a second edge tension threshold when the conveyor belt 102 is supported by the rollers 130 and formed to form the trough 119. The second edge tension threshold can be equal to the first edge tension threshold. The second threshold radius can be equal to the first threshold radius.

[0276] Because the second radius of curvature 258 is equal to or greater than the second threshold radius, the edge tension in the conveyor belt 102 will remain equal to or below the edge tension threshold when the conveyor belt 102 is directed through the concave path corresponding to the concave mounting roller 256. In the event that the edge tension threshold corresponds to a tension exceeding which damage to the conveyor belt 102 is caused, damage to the conveyor belt 102 may be reduced by directing the conveyor belt 102 through the concave path.

[0277] The upper concave roller path 250 and the lower concave roller path 256 form an ascending roller path. The ascending roller path is continuous. Fig.13 , the ascending idler path extends from a first height 260 to a peak height 262. The first height 260 is equal to or greater than the starting height 184. The peak height 262 is greater than the starting height 184. The peak height 262 is greater than the first height 260.

[0278] As the conveyor belt 102 is directed across the first plurality of intermediate trough rollers 196, the conveyor belt 102 is directed through an upward change in height. The upward change in height corresponds to an ascending roller path of the intermediate trough rollers 196 supporting the conveyor belt 102.

[0279] Several of the first plurality of intermediate trough rollers 196 support the conveyor belt 102 through one or more vertical curves 178. In particular, the first plurality of intermediate trough rollers 196 support the conveyor belt 102 through a first upper concave vertical curve 178' and a first lower concave vertical curve 178". By doing so, the first plurality of intermediate trough rollers 196 guide the conveyor belt 102 through an upward height change. Therefore, the conveyor system 100 can be said to guide the conveyor belt 102 through the first upper concave vertical curve 178' and the first lower concave vertical curve 178" at the upward height change.

[0280] The first upper concave vertical curve 178' and the first lower concave vertical curve 178" span at least a portion of the upward height change of the conveyor belt 102. The conveyor belt 102 is supported in the first upper concave vertical curve 178' by a first subset 251 of the first plurality of intermediate trough-shaped rollers 196. The conveyor belt 102 is supported in the first lower concave vertical curve 178" by a second subset 254 of the first plurality of intermediate trough-shaped rollers 196.

[0281] The first concave vertical curve 178' has an associated radius of curvature. The radius of curvature is equal to or greater than a threshold radius. The threshold radius is the radius at which the edge tension of the conveyor belt 102 is below an edge tension threshold when the conveyor belt 102 passes through the first vertical curve 178' formed to form the groove 119. In some embodiments, the threshold radius is approximately 263 meters. In some embodiments, the threshold radius is approximately 100 meters, 200 meters, 220 meters, 240 meters, 260 meters, 280 meters, 300 meters, or 400 meters. In some embodiments, the threshold radius is between 100 meters and 400 meters or between 200 meters and 300 meters.

[0282] The first concave downward vertical curve 178 ″ has an associated radius of curvature. The radius of curvature is equal to or greater than the threshold radius described with reference to the first concave upward vertical curve 178 ′.

[0283] Second plurality of intermediate grooved rollers 210

[0284] refer to Fig.10 , Fig.14 and Fig.16 , the plurality of trough rollers 158 includes a second plurality of intermediate trough rollers 210. In some embodiments, the second plurality of intermediate trough rollers 210 includes a specific number of trough rollers 210. The specific number of trough rollers can be a number greater than or equal to 1. In the illustrated embodiment, the second plurality of intermediate trough rollers 210 includes 13 trough rollers 210. In some embodiments, the first plurality of intermediate trough rollers 196 includes more trough rollers 196 than the second plurality of intermediate trough rollers 210. In some embodiments, the first plurality of intermediate trough rollers 196 includes the same number of trough rollers 196 as the second plurality of intermediate trough rollers 210. In some embodiments, the first plurality of intermediate trough rollers 196 includes fewer trough rollers 196 than the second plurality of intermediate trough rollers 210.

[0285] Multiple trough roller mounting portions 181 include a second plurality of intermediate trough roller mounting portions 212. Support structure 151 includes a second plurality of intermediate trough roller mounting portions 212. Suspension roller support structure 176 includes a plurality of intermediate trough roller mounting portions of the second plurality of intermediate trough roller mounting portions 212. A plurality of intermediate trough rollers of the second plurality of intermediate trough rollers 210 are suspension rollers. These trough rollers may be mounted to suspension roller support structure 176. In some embodiments, all of the intermediate trough rollers of the second plurality of intermediate trough rollers 210 are suspension rollers. In some embodiments, a plurality of intermediate trough rollers of the second plurality of intermediate trough rollers 210 are upright rollers. In these embodiments, these trough rollers 210 may be mounted to the second upright roller support structure.

[0286] One or more trough rollers 210 in the second plurality of intermediate trough rollers 210 may be mounted to corresponding roller mounting portions 212 in the second plurality of intermediate trough roller mounting portions 212. One or more trough rollers 210 in the second plurality of intermediate trough rollers 210 may be mounted to corresponding roller mounting portions 212 in the second plurality of intermediate trough roller mounting portions 212 using bolted engagement.

[0287] When the conveyor belt redirection system 150 is configured, each trough roller 210 of the second plurality of intermediate trough rollers 210 can be said to be supported at a corresponding second intermediate trough roller height 214 (in Fig.11 In other words, the second intermediate trough roller mounting portion 212 is configured to enable the second intermediate trough roller 210 to be mounted at a corresponding second intermediate trough roller height 214. The second intermediate trough roller height 214 is greater than or equal to the end height 194 (in Fig.13 ). Second intermediate trough roller height 214 is greater than or equal to starting height 184. In some embodiments, one or more of second intermediate trough roller heights 214 can be less than one or both of starting height 184 and end height 194.

[0288] When constructing the conveyor belt redirection system 150, it can be said that each of the second plurality of intermediate trough roller mounting sections 212 is positioned at a corresponding second intermediate trough roller mounting section height 216 (at Fig.11 18. Second intermediate trough roller mounting portion height 216 is greater than or equal to starting height 184. Second intermediate trough roller mounting portion height 216 is greater than or equal to end height 194. In some embodiments, one or more of second intermediate trough roller mounting portion heights 216 can be less than one or both of starting height 184 and end height 194.

[0289] In some embodiments, second plurality of intermediate trough roller mounting portions 212 includes a specific number of mounting portions 212. The specific number of mounting portions 212 can be a number greater than or equal to 1. In the illustrated embodiment, second plurality of intermediate trough roller mounting portions 212 includes 13 mounting portions 212. In some embodiments, second plurality of intermediate trough roller mounting portions 212 includes the same number of mounting portions 212 as second plurality of intermediate trough rollers 210 includes trough rollers 210. In some embodiments, second plurality of intermediate trough roller mounting portions 212 includes a different number of mounting portions 212 than second plurality of intermediate trough rollers 210 includes trough rollers 210. For example, in some embodiments, second plurality of intermediate trough roller mounting portions 212 includes a greater number of mounting portions 212 than second plurality of intermediate trough rollers 210 includes trough rollers 210.

[0290] refer to Fig.12 , the second plurality of intermediate trough roller mounting portions 212 are positioned along a second longitudinal length 218 of the conveyor system 100. The second longitudinal length 218 extends parallel to the conveyor longitudinal axis 101. The second longitudinal length 218 is downstream of the first longitudinal length 200. The second longitudinal length 218 can be referred to as a second longitudinal length of the support structure 151. The second longitudinal length 218 can be referred to as a second longitudinal length of the conveyor belt redirection system 150. Therefore, when the second plurality of intermediate trough rollers 210 are mounted to the second plurality of intermediate trough roller mounting portions 212, the second plurality of intermediate trough rollers 210 can be referred to as being positioned along the second longitudinal length 218 of the conveyor belt redirection system 150.

[0291] The second longitudinal length 200 is between the downstream end 206 of the first longitudinal length 200 and the terminal trough roller 190. Thus, the second plurality of intermediate trough roller mounting portions 212 can be said to be between the end of the first longitudinal length 200 and the terminal trough roller 190. Similarly, the second plurality of intermediate trough rollers 210 can be said to be positioned between the downstream end 206 of the first longitudinal length 200 and the terminal trough roller 190. In other words, the second plurality of intermediate trough rollers 210 can be said to be positioned between the end of the first longitudinal length 200 and the terminal trough roller 190.

[0292] When configuring conveyor belt redirection system 150, second plurality of intermediate trough shaped idler mounting sections 212 are positioned at continuously decreasing heights as second longitudinal length 218 traverses from upstream end 220 to downstream end 222. In other words, second intermediate trough shaped idler mounting section heights 216 decrease along second longitudinal length 218. Upstream end 220 of second longitudinal length 218 may correspond to downstream end 206 of first longitudinal length 200. In some embodiments, upstream end 220 of second longitudinal length 218 is separated from downstream end 206 of first longitudinal length 200 by a separation distance.

[0293] Second plurality of intermediate trough roller mounting portions 212 are configured to enable second plurality of intermediate trough rollers 210 to be supported at successively lower heights along second longitudinal length 200. When conveyor belt redirection system 150 is configured, second plurality of intermediate trough rollers 210 are thus supported at successively lower heights along second longitudinal length 218.

[0294] It should be appreciated that in some embodiments, one or more of roller mounting portions 212 of second plurality of intermediate trough shaped roller mounting portions 212 can be positioned at a common height relative to reference plane 146 as immediately preceding roller mounting portion 212. That is, while the height trend of second plurality of intermediate trough shaped roller mounting portions 212 along second longitudinal length 218 can be decreasing in height, it should be appreciated that each roller mounting portion 212 of second plurality of intermediate trough shaped roller mounting portions 212 need not necessarily be at a lower height than immediately preceding roller mounting portion 212.

[0295] It should also be appreciated that in some embodiments, one or more of the trough rollers 210 of the second plurality of intermediate trough rollers 210 may be positioned at a common height relative to the reference plane 146 as the immediately preceding trough roller 210. That is, while the height trend of the second plurality of intermediate trough rollers 210 along the second longitudinal length 218 may be decreasing in height, it should be appreciated that each roller 210 of the second plurality of intermediate trough rollers 212 need not necessarily be at a lower height than the immediately preceding trough roller 210.

[0296] When the conveyor belt redirection system 150 is configured, the second plurality of intermediate trough roller mounting portions 212 are downstream of the first plurality of intermediate trough roller mounting portions 198. In other words, mounting portions 198 of the first plurality of intermediate trough roller mounting portions 198 are closer to the head drum 112 than mounting portions 198 of the first plurality of intermediate trough roller mounting portions 198. When the conveyor belt redirection system 150 is configured, the second plurality of intermediate trough rollers 210 are downstream of the first plurality of intermediate trough rollers 196. In other words, the trough rollers 210 of the second plurality of intermediate trough rollers 210 are closer to the head drum 112 than the trough rollers 196 of the first plurality of intermediate trough rollers 196.

[0297] When mounted to the second plurality of intermediate trough roller mounting portions 212, the second plurality of intermediate trough rollers 210 are spaced apart along the support structure 151. One or more of the second plurality of intermediate trough rollers 210 are spaced apart from adjacent intermediate trough rollers 212 by a second spacing 191. The second spacing 191 is a distance. The second spacing 191 can be measured by connecting the associated intermediate trough rollers 210 with a straight line. The second spacing 191 is associated with the spacing between the roller mounting portions 212. For example, in some embodiments, the associated intermediate trough roller mounting portions 212 are spaced apart by the second spacing 191. Therefore, the corresponding intermediate trough rollers 210 can also be spaced apart by a distance equal to the second spacing 191. Therefore, the second spacing 191 can be measured by connecting the associated intermediate trough roller mounting portions 212 with a straight line.

[0298] In some embodiments, each intermediate trough roller mounting portion of the second plurality of intermediate trough roller mounting portions 212 is separated from adjacent intermediate trough roller mounting portions 212 by the same distance. In some embodiments, each intermediate trough roller of the second plurality of intermediate trough rollers 210 is separated from adjacent intermediate trough rollers 210 by the same distance. In some embodiments, the second spacing 191 is equal to the first spacing 189. In some embodiments, the second spacing 191 is approximately 3 meters. In some embodiments, the second spacing 191 is 1 meter, 1.5 meters, 2 meters, 2.5 meters, 3 meters, 3.5 meters, 4 meters, 4.5 meters, 5 meters, or greater than 5 meters. In some embodiments, the second spacing 191 is between 1 meter and 10 meters or between 2 meters and 5 meters. In some embodiments, the second spacing 191 is proportional to the desired curvature of the conveyor belt 102.

[0299] Second concave installation portion path 242

[0300] refer to Fig.13 , Fig.16 and Fig.18When constructing the support structure 151, the second plurality of intermediate trough shaped roller mounting portions 212 and the end trough shaped roller mounting portions 192 define a concave curve. That is, the second plurality of intermediate trough shaped roller mounting portions 212 and the end trough shaped roller mounting portions 192 define a concave mounting portion path 242. In particular, a curve connecting the corresponding reference points of each mounting portion 212, 192 defines the concave mounting portion path 242. The concave mounting portion path 242 has a concave profile. The concave mounting portion path 242 has a continuous gradient. The concave mounting portion path 242 can be referred to as a second concave mounting portion path 242.

[0301] The gradient of the second recessed mounting portion path 242 decreases along the length of the second recessed mounting portion path 242 in the conveyor system longitudinal direction 109. In other words, the gradient of the second recessed mounting portion path 242 decreases as the second recessed mounting portion path 242 is traversed away from the starting trough roller mounting portion 182 in the conveyor system longitudinal direction 109. The second recessed mounting portion path 242 has a third radius of curvature 244. The third radius of curvature 244 is equal to or greater than the threshold radius. In some embodiments, the third radius of curvature 244 is equal to the second radius of curvature 234. In some embodiments, the third radius of curvature 244 is equal to the first radius of curvature 228.

[0302] Second recessed mounting portion path 242 extends from second peak mounting portion height 246 to a descending mounting portion height 248. Descending mounting portion height 248 is less than second peak mounting portion height 246. Descending mounting portion height 248 is equal to end trough roller mounting portion height 185. In some embodiments, descending mounting portion height 248 is greater than starting height 184. In some embodiments, descending mounting portion height 248 is equal to starting height 184. In some embodiments, descending mounting portion height 248 is less than starting height 184. In some embodiments, first peak mounting portion height 238 is equal to second peak mounting portion height 246. In some embodiments, first peak mounting portion height 238 is greater than second peak mounting portion height 246. This may be the case, for example, if there is one or more idler rollers 130 and / or idler roller mounting portions 182 between second subset 230 of first plurality of intermediate trough roller mounting portions 198 and second plurality of intermediate trough roller mounting portions 212. In some embodiments, first peak mounting portion height 238 is less than second peak mounting portion height 246. In some embodiments, the first recessed mounting portion path 232 and the second recessed mounting portion path 242 are continuous. In some embodiments, the first recessed mounting portion path 232 and the second recessed mounting portion path 242 are discontinuous. For example, one or more rollers 130 and / or roller mounting portions 182 may exist between the first recessed mounting portion path 232 and the second recessed mounting portion path 242.

[0303] Second concave roller path 264

[0304] When the support structure 151 is constructed, the second plurality of intermediate trough rollers 210 and the end rollers 190 define a concave curve. That is, the second plurality of intermediate trough rollers 210 and the end rollers 190 define a concave roller path 264. The concave roller path 264 may be referred to as a second concave roller path 264. The curve connecting the corresponding reference points of each trough roller 210 and the end roller 190 defines the second concave roller path 264. The second concave roller path 264 has a concave profile. The second concave roller path 264 has a continuous gradient. When the conveyor belt 102 is driven across the second plurality of intermediate trough rollers 210 and the end rollers 190, the conveyor belt 102 moves through a curved path corresponding to the second concave roller path 264.

[0305] The gradient of the second concave roller path 264 decreases along the length of the second concave roller path 264 in the conveyor system longitudinal direction 109. In other words, the gradient of the second concave roller path 264 decreases as the second concave roller path 264 is traversed away from the starting trough roller 180 in the conveyor system longitudinal direction 109. The second concave roller path 264 has a third radius of curvature 266. The third radius of curvature 266 is equal to or greater than a third threshold radius. The third threshold radius is the radius at which the edge tension of the conveyor belt 102 is below a second edge tension threshold when the conveyor belt 102 is supported by the rollers 130 and formed to form the trough 119. In some embodiments, the third radius of curvature 266 is equal to one or both of the first radius of curvature 252 and the second radius of curvature 258.

[0306] Since the third radius of curvature 266 is equal to or greater than the third threshold radius, the edge tension in the conveyor belt 102 will remain equal to or below the edge tension threshold when the conveyor belt 102 is guided through the concave path corresponding to the second concave idler path 264. In the case where the edge tension threshold corresponds to a tension exceeding which damage to the conveyor belt 102 is caused, damage to the conveyor belt 102 can be reduced by guiding the conveyor belt 102 through the concave path.

[0307] Second concave roller path 264 extends from second peak height 268 to drop height 270. Drop height 270 is the height of end roller 190. Therefore, drop height 270 is the same as end height 194. Drop height 270 is less than second peak height 268. In some embodiments, drop height 270 is greater than starting height 184. In some embodiments, drop height 270 is equal to starting height 184. In some embodiments, drop height 270 is less than starting height 184. In some embodiments, peak height 262 is equal to second peak height 268. In some embodiments, first concave path 256 and second concave roller path 264 are continuous.

[0308] When the conveyor belt 102 is supported by the conveyor belt redirection system 150, the conveyor belt 102 forms a first upper concave portion 177. The first upper concave portion 177 is at least partially supported by some of the first plurality of intermediate trough rollers 196. The conveyor belt 102 also forms a lower concave portion 179. The first lower concave portion 179 is supported by several of the first plurality of intermediate trough rollers 196 and several of the second plurality of intermediate trough rollers 210.

[0309] Multiple shuttle rollers 138

[0310] When the conveyor belt system 100 is constructed, each shuttle roller 138 can be said to be supported at a corresponding shuttle roller height 272 (at Fig.11 and Fig.13In other words, the shuttle roller mounting portion 137 is configured so that the shuttle roller 138 can be mounted at a corresponding shuttle roller height 272. The shuttle member height 272 is less than the starting height 184 (at Fig.11 Shuttle height 272 is less than end height 194 (shown in FIG. Fig.13 ).

[0311] When constructing the conveyor belt redirection system 150, each shuttle roller mounting section 137 can be referred to as being positioned at a corresponding shuttle roller mounting section height 274 (in Fig.11 and Fig.13 The shuttle roller mounting portion height 274 is lower than the starting trough roller mounting portion height 183 (in Fig.11 The shuttle roller mounting portion height 274 is less than the end groove roller mounting portion height 185 (shown in FIG. Fig.13 ).

[0312] When the conveyor system 100 is configured, the shuttle roller mounting portions 137 are below the second plurality of intermediate trough roller mounting portions 212. Some of the shuttle roller mounting portions 137 are located downstream of the second plurality of intermediate trough roller mounting portions 212. The shuttle 126 is operable such that when the shuttle 126 is in the retracted position 142, several of the shuttle roller mounting portions 137 are positioned below the second plurality of intermediate trough roller mounting portions 212. When the conveyor system 100 is configured, the shuttle rollers 138 are below the second plurality of intermediate trough rollers 210. Some of the shuttle rollers 138 are located downstream of the second plurality of intermediate trough rollers 210. The shuttle 126 is operable such that when the shuttle 126 is in the retracted position 142, several of the shuttle rollers 138 are positioned below the trough rollers 212 of the second plurality of intermediate trough rollers 210.

[0313] As described herein, the conveyor system 100 includes a transition portion 145. The transition portion 145 is a result of the shuttle rollers 138 being disposed at an elevation that is lower than the elevation of the terminal trough rollers 190. However, due to the initial rising and subsequent falling conveyor belt loop upstream of the transition portion 145, the vertical radius traversed by the conveyor belt 102 may be greater than a conveyor system that does not include the described conveyor belt redirection system 150.

[0314] The conveyor belt 102 is guided through a downward height change as the conveyor belt 102 is guided across one or more of the second plurality of intermediate trough rollers 210, the end rollers 190, and the shuttle rollers 138. At least a portion of the downward height change corresponds to a descending roller path of the second plurality of intermediate trough rollers 210 supporting the conveyor belt 102.

[0315] Several of the second plurality of intermediate trough rollers 210 and the end trough rollers 190 support the conveyor belt 102 through one or more vertical curves 178. In particular, the conveyor belt 102 is supported through the second concave vertical curve 178'". By doing so, the intermediate trough rollers 210 guide the conveyor belt 102 through a portion of the downward height change. Therefore, the conveyor system 100 can be said to guide the conveyor belt 102 through the second concave vertical curve 178'" at the downward height change.

[0316] The second concave vertical curve 178'" spans at least a portion of the downward elevation change of the conveyor belt 102. The conveyor belt 102 is supported in the second concave vertical curve 178'" by a second subset 230 of the second plurality of intermediate troughed idler rollers 210.

[0317] The second downward concave vertical curve has an associated radius of curvature. The radius of curvature of the second downward concave vertical curve is equal to or greater than the threshold radius described with reference to the first upward concave vertical curve 178'.

[0318] Third plurality of intermediate grooved rollers

[0319] Figures 3 to 18 The first plurality of intermediate trough rollers 196 and the second plurality of intermediate trough rollers 210 shown in the drawings form a continuous roller path as described herein. It should be understood that in some embodiments, the conveyor belt redirection system 150 may include a third plurality of intermediate trough rollers (not shown). The third plurality of intermediate trough rollers can be supported by the support structure 151. The third plurality of intermediate trough rollers can be supported along an intermediate longitudinal length of the conveyor belt redirection system, which is between the end of the first longitudinal length 200 and the end of the second longitudinal length 218. The associated end of the second longitudinal length 218 can be considered to be the beginning of the second longitudinal length 218. Therefore, the third plurality of intermediate trough rollers can be referred to as being supported and / or disposed between the first plurality of intermediate trough rollers 196 and the second plurality of intermediate trough rollers 210.

[0320] The third plurality of intermediate trough rollers may form one or more of an ascending roller path and a descending roller path. That is, one or more of the third plurality of intermediate trough rollers may be supported by the support structure at a higher height relative to the reference plane 186 than the previous trough roller in the third plurality of intermediate trough rollers. One or more of the third plurality of intermediate trough rollers may be supported by the support structure at a common height with the previous trough roller in the third plurality of intermediate trough rollers relative to the reference plane 186. One or more of the third plurality of intermediate trough rollers may be supported by the support structure at a higher height relative to the reference plane 186 than the previous trough roller in the third plurality of intermediate trough rollers. Therefore, it can be said that the support structure 151 is configured to support one or more of the third plurality of intermediate trough rollers as described herein. Each of the third plurality of intermediate trough rollers may be supported by a corresponding trough roller mounting portion of the support structure 151.

[0321] Conveyor belt redirection systems can be retrofittable

[0322] It will be appreciated that the conveyor belt redirection system 150 may be retrofitted to an already installed conveyor that is subject to accelerated belt wear. For example, where an existing shuttle conveyor is subject to accelerated belt wear due at least in part to height changes in the associated conveyor belt, the described conveyor belt redirection system 150 may be installed to reduce the rate of belt wear. Thus, it will be appreciated that the conveyor belt redirection system 150 may be manufactured and distributed as a module. It will also be appreciated that the conveyor belt redirection system 150 may be distributed without the trough rollers 158, as a user may wish to install the trough rollers according to their own requirements and / or specifications.

[0323] Belt redirection system for increased height

[0324] The conveyor belt redirection system 150 has been described herein in the context of facilitating height reduction. Figures 2 to 18 In the conveyor system 100 , the height of the conveyor belt 102 relative to the reference plane 186 upstream of the transition portion 145 is greater than the height of the conveyor belt 102 relative to the reference plane 186 downstream of the transition portion 145 .

[0325] like Fig.19 As shown, in some embodiments, a similar conveyor belt redirection system 150 helps to increase the height of the conveyor system 100.

[0326] That is, in some embodiments, the height of the conveyor belt 102 relative to the reference plane 186 upstream of the transition portion 145 is lower than the height of the conveyor belt 102 downstream of the transition portion 145 .

[0327] In one embodiment, the transition portion 145 includes a downward height change and a subsequent upward height change, wherein the upward height change is greater than the downward height change. Figures 2 to 18 As stated, Fig.19 The conveyor belt 102 of the embodiment of FIG. 1 is also directed through a number of vertical curves 178 at the transition portion 145 . Fig.19 The conveyor belt redirection system 150 can be configured so that the vertical curve 178 through which the conveyor belt 102 is directed is greater than a threshold radius, which ensures that the edge tension of the conveyor belt 102 is less than or equal to the edge tension threshold of the conveyor belt 102 when the conveyor belt 102 passes through the transition portion 145 to a higher elevation plane.

[0328] It should be understood that Fig.19 The conveyor system 100 is compared with the reference Figures 2 to 18 The conveyor system 100 has features similar or identical to those described herein. Fig.19 Use with Figures 2 to 18 Corresponding features are marked with the same reference numerals.

[0329] Fig. 20 A schematic diagram of another alternative conveyor system 100 is shown. Fig. 20 The conveyor system 100 includes a conveyor belt redirection system 150 that facilitates height increases.

[0330] That is, the height of the conveyor belt 102 relative to the reference plane 186 upstream of the transition portion 145 is lower than the height of the conveyor belt 102 relative to the reference plane 186 downstream of the transition portion 145 .

[0331] exist Fig. 20 In the conveyor system 100, the transition portion 145 includes an upward height change and a subsequent downward height change. The upward height change is greater than the downward height change. Figures 2 to 18 As stated, Fig. 20 The conveyor belt 102 of the embodiment of FIG. 1 is also directed through a number of vertical curves 178 at the transition portion 145 .

[0332] Fig. 20 The conveyor belt redirection system 150 can be configured so that the vertical curve 178 through which the conveyor belt 102 is directed is greater than a threshold radius, which ensures that the edge tension of the conveyor belt 102 is less than or equal to the edge tension threshold of the conveyor belt 102 when the conveyor belt 102 passes through the transition portion 145 to a higher elevation plane.

[0333] It should be understood that Fig. 20 The conveyor system 100 is compared with the reference Figures 2 to 18 The conveyor system 100 has features similar or identical to those described herein. Fig. 20 Use with Figures 2 to 18 Corresponding features are marked with the same reference numerals.

[0334] Embodiments of the conveyor belt redirection system 150 that facilitate height increases may be useful, for example, in response to a sudden upward change in the underlying terrain. Thus, it will also be understood that embodiments of the present disclosure are not limited to shuttle conveyors. That is, embodiments of the present disclosure may be used in conveyor systems that do not include shuttles.

[0335] Conveyor belt redirection system that facilitates undulating terrain

[0336] As described herein, conveyor systems may be subject to various constraints that affect the profile of the conveyor system and / or the conveyor belt loops of the associated conveyor system. One such constraint may be where the conveyor system is required to convey material over terrain that includes changes in elevation (e.g., the top of a slope). A conveyor belt redirection system 150 similar to that described herein may be used to ensure that the radius of the vertical curve 178 through which the conveyor belt 102 is directed when traversing the varying elevation of terrain remains above a threshold radius, thereby reducing edge tension of the conveyor belt 102.

[0337] Fig.21 A schematic diagram of a portion of such a conveyor system 100 is shown.

[0338] It should be understood that Fig.21 The conveyor system 100 is compared with the reference Figures 2 to 18 The conveyor system 100 has features similar or identical to those described herein. Fig.21 Use with Figures 2 to 18 Corresponding features are marked with the same reference numerals.

[0339] For simplicity, the structural features of the conveyor belt redirection system 150 are described in Fig.21 however, an outline of the conveyor belt 102 supported by the conveyor belt redirection system 150 is shown.

[0340] Fig.21 The conveyor system 100 of FIG. 2 passes through a ramp 240. As shown by dashed lines 241 and 243, if the conveyor belt 102 is directed along a linear path to the top 239 of the ramp 240, and is directed to a subsequent linear path after passing the top 239, the conveyor belt 102 will be directed through a sharp corner, which may cause the conveyor belt 102 to pass through a radius of curvature at the top that is less than the recommended operating radius (i.e., the threshold radius) of the conveyor belt 102. As described herein, such a conveyor belt 102 may therefore experience out-of-specification edge tensions and / or accelerated wear.

[0341] Fig.21The conveyor system 100 includes a conveyor belt redirection system 150 to help increase the radius of the vertical curve 178 through which the conveyor belt 102 is directed as it passes over the ramp 240. The conveyor belt redirection system 150 directs the conveyor belt 102 through an initial elevation gain and a subsequent elevation loss. Such elevation gain and elevation loss can be considered relative to a reference plane 186, which can be parallel to the upstream surface of the ramp 240 on which the conveyor belt 102 is directed.

[0342] In other words, the conveyor belt redirection system 150 guides the conveyor belt through an upper concave vertical curve 245 and a subsequent lower concave vertical curve 247 before the top 239. The conveyor belt redirection system 150 guides the conveyor belt 102 through another upper concave vertical curve 249 before the conveyor belt 102 is guided along a linear belt path on the other side of the top 239.

[0343] Thus, the conveyor belt redirection system 150 described herein enables an increase in the radius of curvature through which the conveyor belt 102 is directed when traversing undulating terrain to mitigate the effects of the undulating terrain on the life of the conveyor belt 102 .

[0344] Advantages

[0345] The conveyor system 100 is capable of reducing edge tension in the conveyor belt 102 during operation by at least providing the conveyor belt redirection system 150. The first plurality of intermediate trough rollers 196 are positioned so that the conveyor belt 102 is directed through an ascending path. Subsequently, the conveyor belt 102 is directed through a descending path at the transition portion 145 before being transferred to the shuttle 126. By redirecting the conveyor belt 102 to first ascend and then descend before the conveyor belt 102 is transferred to the shuttle 126, the radius of one or more of the vertical curves 178 that the conveyor belt 102 passes through can be increased relative to a conveyor system that directs the conveyor belt from one horizontal linear belt path directly to another horizontal linear belt path at a lower height without the redirection described herein.

[0346] Thus, the conveyor belt redirection system 150 enables the radius of the vertical curve 178 that the conveyor belt 102 passes through to be increased to or beyond the minimum recommended operating radius. By increasing the radius that the conveyor belt 102 passes through using the described conveyor belt redirection system 150, the edge tension of the conveyor belt 102 at and around the transition portion 145 can be reduced compared to other conveyor systems.

[0347] In some embodiments, the edge tension of the conveyor belt 102 can be reduced by a factor of 4 or less by increasing the radius through which the conveyor belt 102 passes using the described conveyor belt redirection system 150. The significant reduction in edge tension can result in an edge tension below a recommended edge tension threshold.

[0348] The life of the conveyor belt 102 can be increased by increasing the radius of the vertical curve 178 through which the conveyor belt 102 passes toward or beyond the minimum recommended operating radius and / or reducing the edge tension of the conveyor belt toward or below the recommended edge tension threshold. Thus, the described conveyor system 100 can significantly reduce the frequency with which the conveyor belt 102 needs to be replaced. This can result in an increase in the production capacity and / or operating efficiency of a production facility using the conveyor system 100.

[0349] Additionally, reducing the edge tension of the conveyor belt 102 can allow for the use of less expensive conveyor belts. For example, conveyor belts having less belt thickness or reduced mass can be suitable for use with the conveyor system 100 relative to other conveyor systems without significantly increasing the frequency with which the thinner or lighter conveyor belts require repair or replacement.

[0350] As described herein, conveyor systems may be subject to various constraints that affect the profile of the conveyor system and / or the conveyor belt loop of the associated conveyor system. Such conveyor systems may need to include a height change in the path through which the conveyor belt, which is shaped as a groove, moves. For example, in the case of a shuttle conveyor, when the conveyor belt passes through the transition portion from the linear belt path and arrives on the shuttle, it is generally difficult or impossible to reduce the radius through which the conveyor belt is guided because the shuttle makes the necessary movement under the rollers supporting the conveyor belt before the conveyor belt moves onto the shuttle. Specifically, lowering the height of the rollers immediately before the shuttle to increase the radius of curvature through which the conveyor belt is guided is not an option. This is because the gap between these rollers and the shuttle rollers must be able to accommodate the withdrawal of the shuttle from the extended position to the retracted position, and these rollers will not affect the shuttle rollers. The conveyor belt redirection system 150 of the present disclosure enables the radius of the vertical curve 178 through which the conveyor belt 102 is guided to be increased within the originally fixed constraints as a result of the function of the shuttle 126. Similar benefits may be realized where the conveyor belt redirection system 150 is implemented on other conveyor systems that do not necessarily include a shuttle, but do include confined spaces and / or height variations in geometry.

[0351] The conveyor system 100 may also be operated using less energy than a conveyor system that does not include the described conveyor belt redirection system 150. That is, reducing the edge tension of the conveyor belt 102 in the area of ​​the transition portion 145 may provide a reduction in the energy required to move the conveyor belt 102 through the conveyor belt loop 103. For example, by being able to use a conveyor belt having a reduced mass, the energy requirements of the conveyor system 100 may be reduced because less energy is required to move a lighter conveyor belt.

[0352] Many modifications may be made to the embodiments described herein without departing from the spirit and scope of the present disclosure. For example, although the conveyor belt redirection system 150 is described with reference to a conveyor system including the shuttle 126, it should be understood that the redirection conveyor belt as described may also be applicable to other types of conveyors operating at multiple heights and provide comparable advantages thereto.

[0353] In the following claims, as well as in the foregoing description, unless the context requires otherwise due to expressive language or necessary meaning, the word "comprise" or variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. specifying the presence of stated features but not excluding the presence or addition of further features in various embodiments of the present disclosure.

Claims

1. A conveyor system that supports a conveyor belt in a trough shape by a transition section in which the height of the conveyor belt changes, the transition section comprising an upward height change and a subsequent downward height change.

2. The conveyor system according to claim 1, wherein: The downward change in height is greater than the upward change in height.

3. A conveyor system according to claim 1 or claim 2, wherein: The conveyor belt is guided through several vertical curves at the transition section.

4. The conveyor system according to claim 3, wherein: A radius of curvature of one or more of the vertical curves is greater than a threshold radius.

5. A conveyor system according to claim 3 or claim 4, wherein: The conveyor belt is guided through a first upward concave vertical curve and a first downward concave vertical curve at the upward change in height.

6. The conveyor system according to claim 5, wherein: The conveyor belt is guided through a second concave vertical curve at the downward change in level.

7. The conveyor system according to any one of claims 1 to 6, comprising: Multiple grooved rollers; and a support structure to which the plurality of trough rollers are mounted; Wherein, the trough-shaped rollers are configured to support the conveyor belt into the trough shape.

8. The conveyor system according to claim 7, wherein: The plurality of trough rollers includes a first plurality of intermediate trough rollers, the first plurality of intermediate trough rollers including: a first subset of trough rollers, the first subset of trough rollers forming a first upward concave roller path; and A second subset of trough rollers, the second subset of trough rollers forming a first concave roller path.

9. The conveyor system according to claim 8, wherein: The first concave upward roller path defines a first radius of curvature that is greater than a first threshold radius.

10. A conveyor system according to claim 8 or claim 9, wherein: The first concave idler path defines a second radius of curvature that is greater than a second threshold radius.

11. The conveyor system according to any one of claims 8 to 10, wherein: The first upper concave roller path and the first lower concave roller path form a continuous ascending roller path.

12. The conveyor system according to any one of claims 7 to 11, wherein: The plurality of grooved rollers include: a second plurality of intermediate troughed idlers; and End grooved roller; The second plurality of intermediate grooved rollers and the end grooved rollers form a second concave roller path.

13. The conveyor system of claim 12, wherein: The curvature radius of the second concave roller path is greater than a third threshold radius.

14. A conveyor system according to claim 12 or claim 13 when dependent on claim 11, wherein: The ascending roller path and the second concave roller path are continuous.

15. The conveyor system according to any one of claims 12 to 14, wherein: The support structure comprises: -- Upright roller support structure; and -- suspension roller support structure; and The first plurality of intermediate trough rollers includes a plurality of upright rollers mounted to the upright roller support structure; and The second plurality of intermediate trough rollers includes a plurality of suspension rollers mounted to the suspension roller support structure.

16. A conveyor system according to any one of claims 1 to 15, comprising a shuttle, the shuttle comprising: a plurality of shuttle rollers configured to support the conveyor belt; and Head roller; in: The shuttle is configured to move between: extended position; and A retracted position in which one or more of the shuttle rollers are retracted below the transition portion.

17. The conveyor system of claim 16, further comprising a shuttle drive system operably connected to the shuttle, the shuttle drive system operable to move the shuttle between the extended position and the retracted position.

18. A conveyor system according to claim 16 or claim 17 when dependent on claim 12, wherein: Movement of the shuttle from the extended position to the retracted position causes at least one of the plurality of shuttle trough rollers to pass beneath one of the second plurality of intermediate trough rollers.

19. A conveyor belt redirection system comprising: a plurality of trough rollers, the plurality of trough rollers supporting the conveyor belt; and a support structure, the support structure supporting the plurality of grooved rollers; Wherein, the plurality of grooved rollers include: - a starting trough roller, the starting trough roller being supported at a starting height relative to the reference plane; - an end trough roller, the end trough roller being supported at an end height relative to the reference plane; a first plurality of intermediate troughed idlers supported along a first longitudinal length of the conveyor belt redirection system, each successive troughed idler in the first plurality of intermediate troughed idlers being supported at a greater height relative to the reference plane than a preceding troughed idler in the first plurality of intermediate troughed idlers; and a second plurality of intermediate trough rollers supported along a second longitudinal length of the conveyor belt redirection system, the second longitudinal length being between an end of the first longitudinal length and the terminal trough roller, each successive trough roller of the second plurality of intermediate trough rollers being supported at a lower height relative to the reference plane than a preceding trough roller of the second plurality of intermediate trough rollers.

20. A conveyor belt redirection system comprising: A plurality of trough rollers configured to support a conveyor belt, the plurality of trough rollers comprising: --Starting grooved roller; --a first plurality of intermediate grooved rollers; - a second plurality of intermediate grooved rollers; and -- end grooved rollers; and A support structure, the support structure being configured to: -- supporting the starting grooved roller at a starting height relative to the reference plane; -- supporting the end grooved roller at the end height relative to the reference plane; -- supporting the first plurality of intermediate trough-shaped idlers at successively increasing heights relative to the reference plane along a first longitudinal length of the conveyor belt redirection system, the successively increasing heights being greater than the starting height; and --Supporting a second plurality of intermediate trough rollers at continuously decreasing heights relative to the reference plane along a second longitudinal length of the conveyor belt redirection system, wherein the second longitudinal length is located between an end of the first longitudinal length and the terminal trough roller, and the continuously decreasing height is greater than the terminal height.

21. A conveyor belt redirection system according to claim 19 or claim 20, wherein: The first plurality of intermediate troughed idler rollers includes a first subset of troughed idler rollers that form a first upward concave idler roller path.

22. The conveyor belt redirection system of claim 21, wherein: The first concave upward roller path defines a first radius of curvature that is greater than a first threshold radius.

23. A conveyor belt redirection system according to any one of claims 19 to 22, wherein: The first plurality of intermediate troughing rollers includes a second subset of troughing rollers forming a first concave roller path.

24. The conveyor belt redirection system of claim 23, wherein: The first concave idler path defines a second radius of curvature that is greater than a second threshold radius.

25. A conveyor belt redirection system according to claim 23 or claim 24 when dependent on claim 3 or claim 4, wherein: The first upper concave roller path and the first lower concave roller path form a continuous ascending roller path.

26. The conveyor belt redirection system of claim 25, wherein: The raised idler path extends from a first height relative to the reference plane that is equal to or greater than the starting height to a peak height relative to the reference plane that is greater than the starting height.

27. A conveyor belt redirection system according to any one of claims 19 to 26, wherein: The second plurality of intermediate troughed rollers and the end troughed rollers form a second concave roller path.

28. The conveyor belt redirection system of claim 27, wherein: The curvature radius of the second concave roller path is greater than a third threshold radius.

29. A conveyor belt redirection system according to claim 28 when dependent on claim 24, wherein: The third threshold radius is equal to the second threshold radius.

30. A conveyor belt redirection system according to any one of claims 27 to 29, wherein: The second concave roller path extends from a second peak height relative to the reference plane to a dropped height relative to the reference plane, the dropped height being less than the second peak height.

31. A conveyor belt redirection system according to claim 30 when dependent on claim 26, wherein: The peak height and the second peak height are equal.

32. A conveyor belt redirection system according to any one of claims 27 to 31 when dependent on claims 21 and 23, wherein: The ascending roller path and the second concave roller path are continuous.

33. A conveyor belt redirection system according to claim 19 or any one of claims 21 to 32 when dependent on claim 19, wherein: the plurality of trough rollers including a third plurality of intermediate trough rollers supported along an intermediate longitudinal length of the conveyor belt redirection system, the intermediate longitudinal length being between an end of the first longitudinal length and an end of the second longitudinal length; and One or more of the third plurality of intermediate trough rollers are supported by the support structure on: - at a height relative to the reference plane that is greater than a preceding troughed roller in the third plurality of intermediate troughed rollers; - at a common height relative to the reference plane with a preceding troughed roller of the third plurality of intermediate troughed rollers; or - at a lower height relative to the reference plane than a previous troughed roller in the third plurality of intermediate troughed rollers.

34. A conveyor belt redirection system according to claim 20 or any one of claims 21 to 32 when dependent on claim 20, wherein: The plurality of trough rollers includes a third plurality of intermediate trough rollers; and The support structure is configured to support one or more of the third plurality of intermediate trough rollers along an intermediate longitudinal length of the conveyor belt redirection system between the end of the first longitudinal length and the end of the second longitudinal length at: - at a height relative to the reference plane that is greater than a preceding troughed roller in the third plurality of intermediate troughed rollers; - at a common height relative to the reference plane as the preceding troughed roller of the third plurality of intermediate troughed rollers; or At a lower height relative to the reference plane than a previous troughed roller in the third plurality of intermediate troughed rollers.

35. A conveyor belt redirection system according to any one of claims 19 to 34, wherein: The first plurality of intermediate trough rollers includes a plurality of upright rollers configured to be mounted to an upright roller support structure.

36. A conveyor belt redirection system according to any one of claims 19 to 35, wherein: The second plurality of intermediate trough rollers includes a plurality of suspension rollers configured to be mounted to a suspension roller support structure.

37. A conveyor belt redirection system according to any one of claims 19 to 36, wherein: The plurality of trough rollers are configured to support the conveyor belt so that the conveyor belt forms: troughs for holding materials; an upper concave portion, the upper concave portion being at least partially supported by some of the first plurality of intermediate trough-shaped idlers; and A concave portion, wherein: --extending from an end of the first upper concave portion; and -- supported by a plurality of the first plurality of intermediate trough-shaped rollers and a plurality of the second plurality of intermediate trough-shaped rollers.

38. The conveyor belt redirection system of any one of claims 19 to 37, further comprising a shuttle, the shuttle comprising: A shuttle body; a plurality of shuttle groove rollers, the plurality of shuttle groove rollers being mounted to the shuttle body; and A head roller, the head roller is mounted to the shuttle body; in: The shuttle is configured to move between: - extended position; and a retracted position in which the head roller is closer to the starting grooved roller than when the shuttle is in the extended position; and In each of the extended position and the retracted position, one or more of the plurality of shuttling trough rollers is at a height relative to the reference plane that is less than a height of each of the second plurality of trough rollers.

39. The conveyor belt redirection system of claim 38, wherein: Movement of the shuttle from the extended position to the retracted position causes at least one of the plurality of shuttle trough rollers to pass beneath one of the second plurality of intermediate trough rollers.

40. A conveyor belt redirection system according to claim 38 or claim 39, further comprising a shuttle drive system configured to be connected to the shuttle, the shuttle drive system being operable to move the shuttle between the extended position and the retracted position.

41. A conveyor belt redirection system according to any one of claims 19 to 40, wherein: The support structure comprises: a starting grooved roller mounting portion, to which the starting grooved roller can be mounted; an end grooved roller mounting portion, to which the end grooved roller can be mounted; a first plurality of intermediate troughed roller mounting sections, the first plurality of intermediate troughed roller mounting sections being positioned at successively increasing heights relative to the reference plane along the first longitudinal length of the conveyor belt redirection system, each of the first plurality of intermediate troughed rollers being mountable to a respective one of the first plurality of intermediate troughed roller mounting sections; and and a second plurality of intermediate trough roller mounting portions, wherein the second plurality of intermediate trough roller mounting portions are positioned at successively lower heights relative to the reference plane along the second longitudinal length of the conveyor belt redirection system, and each of the second plurality of intermediate trough rollers is mountable to a respective one of the second plurality of intermediate trough roller mounting portions.

42. A support structure comprising: a starting trough roller mounting portion configured to enable a starting trough roller to be mounted at a starting height relative to a reference plane; a terminal trough roller mounting portion configured to enable a terminal trough roller to be mounted at a terminal height relative to the reference plane; a first plurality of intermediate trough shaped idler mounting sections, the first plurality of intermediate trough shaped idler mounting sections being positioned along a first longitudinal length of the support structure, the first plurality of intermediate trough shaped idler mounting sections being configured to enable the first plurality of intermediate trough shaped idler rollers to be positioned at successively increasing heights relative to the reference plane that are greater than the starting height; and and a second plurality of intermediate trough roller mounting portions, the second plurality of intermediate trough roller mounting portions being positioned along a second longitudinal length of the support structure, the second plurality of intermediate trough roller mounting portions being configured to enable a second plurality of intermediate trough rollers to be positioned at continuously decreasing heights greater than the end height relative to the reference plane along the second longitudinal length of the support structure, the second longitudinal length being between an end of the first longitudinal length and the end trough roller.

43. A support structure according to claim 42, wherein: When constructing the support structure: The starting trough roller mounting portion is positioned relative to the reference plane at a starting trough roller mounting portion height; The end trough roller mounting portion is positioned relative to the reference plane at the end trough roller mounting portion height; The first plurality of intermediate trough roller mounting portions are positioned at successively increasing heights relative to the reference plane, the successively increasing heights being greater than the starting trough roller mounting portion height; and The second plurality of intermediate troughed roller mounting portions are positioned at successively decreasing heights relative to the reference plane, the successively decreasing heights being greater than the terminal troughed roller mounting portion heights.

44. A support structure according to claim 42 or 43, wherein: When the support structure is constructed, a first subset of the first plurality of intermediate trough-shaped idler mounting portions defines a first upper concave mounting portion path.

45. A support structure according to claim 44, wherein: The first concave mounting portion path has a first radius of curvature greater than a first threshold radius.

46. ​​A support structure according to any one of claims 42 to 45, wherein When the support structure is constructed, a second subset of the first plurality of intermediate channeled idler mounting portions defines a first recessed mounting portion path.

47. A support structure according to claim 46, wherein: The first recessed mounting portion path defines a second radius of curvature that is greater than a second threshold radius.

48. A support structure according to claim 46 or claim 47 when dependent on claim 44 or claim 45, wherein The first upward concave mounting portion path and the first downward concave mounting portion path form an ascending mounting portion path.

49. A support structure according to claim 48, wherein The ascending mounting portion path extends from a first mounting portion height relative to the reference plane that is equal to or greater than the starting height to a peak mounting portion height relative to the reference plane that is greater than the starting height.

50. A support structure according to any one of claims 42 to 49, wherein: When the support structure is constructed, the second plurality of intermediate trough-shaped idler mounting portions form a second concave mounting portion path.

51. A support structure according to claim 50, wherein: The second concave mounting portion path defines a third radius of curvature that is greater than a third threshold radius.

52. A support structure according to claim 51 when dependent on claim 47, wherein The third threshold radius is equal to the second threshold radius.

53. A support structure according to any one of claims 50 to 52, wherein: The second recessed mounting portion path extends from a second peak mounting portion height relative to the reference plane to a dropped mounting portion height relative to the reference plane, the dropped mounting portion height being less than the second peak mounting portion height.

54. A support structure according to claim 53 when dependent on claim 49, wherein: The peak mounting portion height and the second peak mounting portion height are equal.

55. A support structure according to any one of claims 46 to 54, wherein The first recessed mounting portion path and the second recessed mounting portion path are continuous.

56. A support structure according to any one of claims 42 to 54, further comprising: a third plurality of intermediate trough roller mounting portions, the third plurality of intermediate trough roller mounting portions being positioned along an intermediate longitudinal length of the support structure, the intermediate longitudinal length being between the end of the first longitudinal length and the end of the second longitudinal length, the third plurality of intermediate trough roller mounting portions being configured to enable one or more of the third plurality of intermediate trough rollers to be supported on: - at a height relative to the reference plane that is greater than a preceding troughed roller in the third plurality of intermediate troughed rollers; - at a common height relative to the reference plane with a preceding troughed roller of the third plurality of intermediate troughed rollers; or - at a lower height relative to the reference plane than a previous troughed roller in the third plurality of intermediate troughed rollers.

57. The support structure of any one of claims 42 to 56, further comprising a shuttle support portion configured to support the shuttle when: when the shuttle is in an extended position; When the shuttle is in the retracted position, wherein the nose roller of the shuttle is closer to the starting grooved roller mounting portion than when the shuttle is in the extended position; and When the shuttle moves between the extended position and the retracted position.

58. A conveyor belt redirection system comprising: A support structure according to any one of claims 42 to 57; and A plurality of grooved rollers, the plurality of grooved rollers comprising: --The starting grooved roller; --The end grooved roller; - said first plurality of intermediate grooved rollers; and --The second plurality of intermediate grooved rollers.

59. A conveyor belt redirection system according to claim 58 when dependent on claim 56, further comprising said third plurality of intermediate troughed idlers.

60. A conveyor belt redirection system according to claim 58 or claim 59, wherein: The support structure further includes an upright roller support structure, and the first plurality of trough rollers includes a plurality of upright rollers configured to be mounted to the upright roller support structure.

61. A conveyor belt redirection system according to any one of claims 58 to 60, wherein: The support structure further includes a suspension roller support structure, and the second plurality of trough rollers includes a plurality of suspension rollers configured to be mounted to the suspension roller support structure.

62. A conveyor belt redirection system according to any one of claims 58 to 61, wherein: The plurality of trough rollers are configured to support a conveyor belt such that the conveyor belt forms: troughs for holding materials; an upper concave portion, the upper concave portion being at least partially supported by one or more of the first plurality of intermediate trough-shaped idlers; and A concave portion is supported by a plurality of the first plurality of intermediate trough-shaped rollers and a plurality of the second plurality of intermediate trough-shaped rollers.

63. A conveyor system comprising: A conveyor belt redirection system according to any one of claims 19 to 41 or 58 to 62; or A support structure according to any one of claims 42 to 57.

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