Novel self-powered carrier roller

Abstract

The utility model provides a novel self-powered carrier roller which comprises a roller body, a roller shaft, a first supporting group, a second supporting assembly and a stator, a rotor and a circuit board are arranged in the first supporting assembly, a wireless communication module is integrated on the circuit board and is electrically connected with a sensor assembly, the stator is arranged on the roller shaft, and the first supporting assembly and the second supporting assembly are connected through a wireless communication module. By means of relative movement between the roller body and the roller shaft, the stator and the rotor rotate relatively, electric energy is generated, power is supplied to the circuit board and the sensor assembly, the sensor assembly can monitor the running state of the carrier roller in real time, monitoring data are sent to a control system through the wireless communication module, and once a conveying system breaks down, the control system is started. According to the monitoring data information, a fault point can be quickly and accurately positioned.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of rollers, in particular to a self-powered novel roller. BACKGROUND

[0002] Rollers are widely used in the fields of industry and agriculture, for example, long-distance coal conveying. During the operation of the roller, the following faults are common: roller barrel wear, bearing damage, roller bending deformation, and roller barrel and bearing seat cracking, bearing disengagement, etc. However, the conventional roller has the problems of being unable to discover the fault problem point in time, difficulty in fault positioning, and lack of monitoring means when the fault occurs, especially in long-distance conveying schemes. CONTENT OF THE UTILITY MODEL

[0003] In order to solve the above technical problems, the application provides a self-powered novel roller, which comprises:

[0004] a roller barrel body;

[0005] a roller shaft arranged in the roller barrel body and having relative movement with the roller barrel body;

[0006] a first support assembly sleeved at one end of the roller shaft, the first support assembly comprising a rotor and a circuit board; the circuit board is integrated with a wireless communication module and electrically connected with a sensor assembly;

[0007] a second support assembly sleeved at the other end of the roller shaft;

[0008] and a stator fixedly arranged on the roller shaft and having relative movement with the rotor to generate electric energy and supply power to the circuit board and the sensor assembly.

[0009] In some embodiments of the application, the first support assembly further comprises a first support seat, a first sealing cover and a first bearing; the first sealing cover is arranged at the end of the first support seat; and the first bearing is arranged at one end of the first support seat close to the first sealing cover.

[0010] In some embodiments of the application, the first support seat comprises an outer support portion and an inner support portion, and a plurality of mounting groove groups arranged along the circumferential direction of the inner support portion are formed between the outer support portion and the inner support portion.

[0011] In some embodiments of the application, the mounting groove groups comprise a plurality of first mounting grooves and a second mounting groove arranged between adjacent two first mounting grooves.

[0012] In some embodiments of the present application, the sensor assembly comprises a first pressure sensor and a second pressure sensor arranged in the second mounting groove; and an angle between the first pressure sensor, the second pressure sensor and a line connecting the center of the inner support part is a right angle.

[0013] In some embodiments of the present application, the sensor assembly comprises a position detection sensor arranged in the first mounting groove.

[0014] In some embodiments of the present application, the second support assembly comprises a second support seat, a second bearing and a second sealing cover; the second sealing cover is arranged at an end of the second support seat, and the second bearing is arranged in the second support seat.

[0015] In some embodiments of the present application, the sensor assembly further comprises a millimeter wave radar or an ultrasonic radar, and the millimeter wave radar or the ultrasonic radar is arranged in the first mounting groove.

[0016] In some embodiments of the present application, the first support assembly further comprises a third bearing arranged in the first support seat.

[0017] In some embodiments of the present application, the sensor assembly further comprises a temperature sensor arranged on or near an outer ring of the first bearing or the third bearing.

[0018] Compared with the prior art, the self-powered novel idler of the present application has the following advantages and beneficial effects: the self-powered novel idler of the present application is provided with a first support assembly, a rotor and a circuit board are arranged in the first support assembly, a wireless communication module is integrated on the circuit board and electrically connected with a sensor assembly, a stator is arranged on a roller shaft, relative rotation between the stator and the rotor is caused by relative movement between a roller body and the roller shaft, electric energy is generated to supply power to the circuit board and the sensor assembly, the sensor assembly can monitor the running state of the idler in real time, and monitoring data is sent to a control system through the wireless communication module, once a fault occurs in a conveying system, the fault point can be quickly and accurately located according to the monitoring data.

[0019] It should be understood that the foregoing general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. BRIEF DESCRIPTION OF DRAWINGS

[0020] The accompanying drawings, which form a part of the present application, are intended to provide further understanding of the present application, and the illustrative embodiments thereof and the description thereof serve to explain the present application, and do not constitute improper limitations on the present application. In the drawings:

[0021] Figure 1 is a sectional view of the self-powered novel idler provided by an exemplary embodiment of the present application;

[0022] Figure 2 is a sectional view of a first support assembly provided by an example embodiment of the present application;

[0023] Figure 3 is a structural schematic view of a first support seat provided by an example embodiment of the present application;

[0024] Figure 4 is a front view of the first support seat provided by an example embodiment of the present application.

[0025] in the figure:

[0026] 101, roller body; 102, roller shaft; 103, first support assembly; 1031, first support seat; 1031a, outer support part; 1031b, inner support part; 1031c, first mounting groove; 1031d, second mounting groove; 1032, first sealing cover; 1033, rotor; 1034, circuit board; 1035, first bearing; 1036, third bearing; 1037, third sealing cover; 104, second support assembly; 1041, second support seat; 1042, second bearing; 1043, second sealing cover; 105, stator; 106, sensor assembly; 107, battery. DETAILED DESCRIPTION

[0027] In order to make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application. It should be noted that, in the case of no conflict, the embodiments in the present application and the features in the embodiments can be combined with each other at will.

[0028] The carrier roller is widely used in the fields of industry and agriculture, for example, long-distance coal conveying. During the operation of the carrier roller, the following common faults occur, such as carrier roller roller wear, bearing damage, carrier roller bending deformation, and roller and bearing seat cracking, bearing falling out, etc. However, the traditional carrier roller has the problems of being unable to find fault problem points in time, great difficulty in fault positioning, lack of monitoring means, etc. when a fault occurs, especially in long-distance conveying schemes.

[0029] Based on this, the example embodiment of the present application provides a self-powered novel carrier roller. A first supporting assembly is arranged, a rotor and a circuit board are arranged in the first supporting assembly, a wireless communication module is integrated on the circuit board and is electrically connected with a sensor assembly, a stator is arranged on a roller shaft, relative rotation between the stator and the rotor is caused by relative movement between a roller body and the roller shaft, electric energy is generated to supply power to the circuit board and the sensor assembly, the sensor assembly can monitor the running state of the carrier roller in real time, and the monitoring data is sent to a control system through the wireless communication module. Once a fault occurs in the conveying system, the fault point can be quickly and accurately located according to the monitoring data information.

[0030] The example embodiment of the present application provides a self-powered novel carrier roller, as Figure 1As shown, the carrier roller comprises a roller body 101, a roller shaft 102, a first support assembly 103, a second support assembly 104 and a stator 105; the roller shaft 102 is arranged in the roller body 101 and has relative movement with the roller body 101, for example, the roller body 101 rotates and the roller shaft 102 does not rotate; the first support assembly 103 is sleeved on one end of the roller shaft 102, the first support assembly 103 comprises a rotor 1033 and a circuit board 1034, the rotor 1033 comprises a plurality of groups of coils arranged around the roller shaft 102; the circuit board 1034 is integrated with a wireless communication module and electrically connected with a sensor assembly 106; the second support assembly 104 is sleeved on the other end of the roller shaft 102; the stator 105 is fixedly arranged on the roller shaft 102, preferably, the wireless communication module can use a wireless communication module in the prior art, for example, a WIFI, NBIOT module or a LORA module; the stator 105 comprises a plurality of groups of magnets arranged around the roller shaft 102, the stator 105 is arranged at intervals with the rotor 1033 and has relative movement with the rotor 1033, so that the rotor 1033 can cut the magnetic induction lines in the process of following the rotation of the roller body 101, thereby generating electric energy, the stator 105 and the rotor 1033 form a generator to supply power to the circuit board 1034 and the sensor assembly 106, and the number of pulses of the generator and the stator can also be used to measure the rotating speed of the carrier roller. The first support assembly 103 can also comprise a battery 107, the battery 107 is arranged in the first support seat 1031 and electrically connected with the circuit board 1034 and the sensor assembly, as a backup power supply; at the same time, the battery 107 and the rotor 1033 are electrically connected through a rectification and voltage stabilization circuit, so as to charge the battery 107. If the carrier roller fails during operation, at this time, the rotor 1033 cannot rotate, the generator cannot generate electric energy, if the battery 107 is arranged, the battery 107 can supply power to the circuit board 1034 and the sensor assembly 106, so that the sensor assembly 106 can continuously detect the state of the carrier roller. Of course, the battery 107 can also not be arranged, at this time, if the carrier roller fails during operation, the circuit board 1034 and the sensor assembly 106 cannot work due to the lack of power supply, therefore, the control system cannot receive the data of the sensor assembly 106 of the carrier roller, so that it can be judged that the carrier roller has a fault. The sensor assembly 106 can monitor the running state of the carrier roller in real time, realize self-monitoring of the running state of the carrier roller, and send the monitoring data to the control system through the wireless communication module, once the conveying system fails, according to the monitoring data information, the fault point can be quickly and accurately located.

[0031] As Figure 1As shown in FIG. 2, the first support assembly 103 further comprises a first support seat 1031, a first sealing cover 1032, and a first bearing 1035. The first sealing cover 1032 is arranged at an end of the first support seat 1031. The first bearing 1035 is arranged at an end of the first support seat 1031 close to the first sealing cover 1032. The rotor 1033 is arranged at an end of the first support seat 1031 away from the first sealing cover 1032. In order to prevent the rotor 1033 from being detached during operation, a third sealing cover 1037 or a third bearing 1036 is arranged at a side of the rotor 1033. The third sealing cover 1037 is arranged at the other end of the first support seat 1031. The third bearing 1036 is arranged at an end of the first support seat 1031 away from the first sealing cover 1032. The second support assembly 104 comprises a second support seat 1041, a second bearing 1042, and a second sealing cover 1043. The second sealing cover 1043 is arranged at an end of the second support seat 1041. The second bearing 1042 is arranged in the second support seat 1041. The first support assembly 103 and the second support assembly 104 jointly support the roller shaft 102 and the roller body 101.

[0032] As Figure 3 and 4As shown, the first support seat 1031 comprises an outer support part 1031a and an inner support part 1031b, mounting spaces for mounting the first bearing 1035, the rotor 1033 and the third bearing 1036 are formed on both sides of the inner support part 1031b, and mounting groove groups arranged along the circumferential direction of the inner support part 1031b are formed between the outer support part 1031a and the inner support part 1031b. The mounting groove groups comprise a plurality of first mounting grooves 1031c and a second mounting groove 1031d arranged between two adjacent first mounting grooves 1031c. The circuit board 1034 is mounted in the first mounting groove 1031c. The sensor assembly 106 can comprise various types of sensors to monitor the temperature, weight and other parameters of the carrier roller in real time. The sensor assembly 106 comprises a first pressure sensor and a second pressure sensor arranged in the second mounting groove 1031d, and a position detection sensor arranged in the first mounting groove 1031c. The included angle between the first pressure sensor, the second pressure sensor and the line connecting the center of the inner support part 1031b is a right angle. The relative positions between the position detection sensor and the first pressure sensor and the second pressure sensor are determined to determine the positions of the first pressure sensor and the second pressure sensor. The position detection sensor can be a gyroscope or a Hall sensor. When the position detection sensor detects that the first pressure sensor is above in the vertical direction, the second pressure sensor is in the horizontal direction. At this time, the control system controls the first pressure sensor and the second pressure sensor to measure data. In this way, the first pressure sensor in the vertical direction is in a pressure state, and the second pressure sensor in the horizontal direction is in a tension state. The deformation of the carrier roller is calculated by the measurement data of the first pressure sensor and the second pressure sensor, and the weight borne by the carrier roller is calculated, so that the weight borne by the carrier roller is monitored in real time.

[0033] The sensor assembly 106 can also include a millimeter wave radar or an ultrasonic radar arranged in the first mounting groove 1031c, which can detect whether there is a belt above the roller, and further determine whether the belt is deviated during operation. When the millimeter wave radar is used for monitoring, the first support seat 1031 and the roller body 101 are made of a high polymer or other wear-resistant material, and are not suitable for being made of metal. In an embodiment, the sensor assembly 106 can also include a temperature sensor for monitoring the temperature of each component inside the roller in real time, preventing damage to the components caused by excessive temperature. For example, the temperature sensor is arranged on or near the outer ring of the first bearing 1035 or the third bearing 1036 to monitor the temperature of the first bearing 1035 or the second bearing 1042 in real time. The first support seat 1031 can also be divided into a first segment and a second segment connected detachably and connected by fasteners. At this time, there is a gap between the first segment and the second segment, and the temperature sensor can be arranged in the gap to monitor the temperature of the roller body 101. The temperature sensor can also be arranged on the circuit board 1034 to monitor the temperature of the circuit board 1034 in real time. In another example embodiment, the sensor assembly also includes a gas or smoke sensor. The first mounting groove 1031c is provided with an air inlet hole near one side of the first sealing cover 1032. The gas or smoke sensor is installed in the first mounting groove 1031c and is filled with glue to fix and block the sensor. The gas or smoke sensor can monitor the concentration of smoke, flammable gas or harmful gas near the belt.

[0034] In this application, the terms "comprise", "contain", or any other variant thereof are intended to cover non-exclusive inclusion, so that the articles or devices including a series of elements not only include those elements, but also include other elements not explicitly listed or inherent to such articles or devices. Without more limitations, the elements defined by the statement "comprise" do not exclude the presence of other identical elements in the articles or devices including the elements.

[0035] Although the preferred embodiments of the present application have been described, those skilled in the art can make further changes and modifications to the embodiments once they know the basic inventive concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0036] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application also intends to include these modifications and variations.

Claims

1. A novel self-powered idler roller, characterized in that, include: Roller body; A roller shaft is disposed within the roller body and has relative movement with respect to the roller body; A first support assembly is sleeved on one end of the roller shaft. The first support assembly includes a rotor and a circuit board. The circuit board integrates a wireless communication module and is electrically connected to a sensor assembly. The second support assembly is sleeved on the other end of the roller shaft; The stator is fixedly mounted on the roller shaft and has relative motion with the rotor, generating electrical energy to power the circuit board and sensor assembly.

2. The self-powered novel idler roller according to claim 1, characterized in that, The first support assembly further includes a first support base, a first sealing cover, and a first bearing; the first sealing cover is disposed at the end of the first support base; the first bearing is disposed inside the first support base at one end near the first sealing cover.

3. The self-powered novel idler roller according to claim 2, characterized in that, The first support base includes an outer support portion and an inner support portion, and an assembly of mounting grooves arranged along the circumferential direction of the inner support portion is formed between the outer support portion and the inner support portion.

4. The self-powered novel idler roller according to claim 3, characterized in that, The mounting slot group includes a plurality of first mounting slots and a second mounting slot disposed between two adjacent first mounting slots.

5. The self-powered novel idler roller according to claim 4, characterized in that, The sensor assembly includes a first pressure sensor and a second pressure sensor disposed in the second mounting slot; the angle between the line connecting the first pressure sensor, the second pressure sensor and the center of the inner support is a right angle.

6. The self-powered novel idler roller according to claim 4, characterized in that, The sensor assembly includes a position detection sensor, which is disposed in the first mounting slot.

7. The self-powered novel idler roller according to claim 1, characterized in that, The second support assembly includes a second support base, a second bearing, and a second sealing cover; the second sealing cover is disposed at the end of the second support base, and the second bearing is disposed inside the second support base.

8. The self-powered novel idler roller according to claim 4, characterized in that, The sensor assembly also includes a millimeter-wave radar or an ultrasonic radar, which is disposed in the first mounting slot.

9. The self-powered novel idler roller according to claim 2, characterized in that, The first support assembly further includes a third bearing, which is disposed within the first support base.

10. The self-powered novel idler roller according to claim 9, characterized in that, The sensor assembly also includes a temperature sensor disposed on or near the outer ring of the first bearing or the third bearing.

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