Self-powered intelligent idler roller

Abstract

This utility model discloses a self-powered intelligent idler roller, comprising a roller, an idler shaft, and bearings. A bearing seat is fixedly installed at each end inside the roller, and the bearing seats are fixed to the idler shaft via bearings. The bearing seats and retaining rings, together with the stator and rotor, form a labyrinth seal structure to block external impurities. A PCB board is embedded in the stator, integrating an induction coil, a rectifier module, a multi-parameter sensor, and a signal transmission module. This utility model achieves high-efficiency energy conversion and low-loss operation through an integrated magneto-electric and sealed design, solving the pain point of traditional solutions relying on external power supply or batteries. This utility model combines three major advantages: real-time performance, reliability, and long lifespan, providing an innovative solution for intelligent monitoring of industrial equipment.

Description

Technical Field

[0001] This utility model belongs to the field of centrifugal separation technology, and specifically relates to a self-powered intelligent idler roller. Background Technology

[0002] Idler rollers are crucial components of belt conveyors. They come in many types and are numerous, supporting the conveyor belt and the weight of materials. A single belt conveyor typically has many idlers. The proper functioning of the idlers directly affects the conveyor's overall condition. Currently, idler monitoring is mostly achieved through manual inspection. This method lacks real-time observation and lifespan prediction capabilities, and initial idler failures cannot be visually detected. Often, idler failures are only discovered after they occur, and replacing idlers is hampered by delivery delays and high inventory costs.

[0003] Intelligent monitoring of belt conveyor idlers is a core requirement of industrial intelligent monitoring. Existing technologies mainly fall into two categories: one is an externally powered sensor solution, in which the sensor is installed on the outside of the idler and energy is transferred to the sensor through an external power supply; the other is a battery-powered external sensor solution, in which the sensor is powered by a battery.

[0004] External sensors relying on external power supply require additional wiring or complex mechanical structures, leading to high installation and maintenance costs and susceptibility to instability caused by harsh environments such as dust and vibration. Battery-powered external sensors are limited by signal detection frequency, necessitating intermittent monitoring of the self-powered intelligent idler roller's operating data to extend battery life or requiring frequent battery replacements. This results in high maintenance costs and the need for calibration after each installation, impacting monitoring stability. Furthermore, the external sensors are located far from the monitored component (idler roller bearing), meaning all data is indirectly obtained and not entirely accurate, suffering significant distortion due to various factors. Utility Model Content

[0005] Based on the technical problems existing in the prior art, this utility model provides a self-powered intelligent idler roller, which integrates a magnetoelectric conversion power generation module and multi-parameter sensors within a sealed structure to achieve real-time monitoring without external power supply.

[0006] According to the technical solution of this utility model, this utility model provides a self-powered intelligent idler roller. The self-powered intelligent idler roller adopts a symmetrical structure and includes a roller, an idler shaft, and bearings. A bearing seat is fixedly installed at each end inside the roller. The bearing seat is fixed to the idler shaft by the bearing. The bearing seat and the retaining ring, together with the stator and rotor, form a labyrinth seal structure to block external impurities. The stator has an embedded PCB board, which integrates an induction coil, a rectifier module, a multi-parameter sensor, and a signal transmission module. The stator is installed at both ends of the idler shaft and is fixed to the circumference of the idler shaft.

[0007] Preferably, the roller adopts a hollow cylindrical design, with an outer diameter of φ89mm-800mm and a length set according to the width of the conveyor belt.

[0008] Preferably, the roller and the bearing housing together form the rotating component of the idler roller, and the roller and the bearing housing are connected and fixed by welding, interference fit or spinning.

[0009] Preferably, the bearing housing is used to fix the bearing position and ensure that the idler roller shaft and the roller are coaxial.

[0010] More preferably, retaining rings are installed at both ends of the idler roller shaft for axial fixation of the stator.

[0011] Furthermore, the slots at both ends of the idler roller shaft are equipped with shaft elastic retaining rings, which are made of 65Mn steel and whose diameter matches that of the idler roller shaft.

[0012] Furthermore, the stator is pressed and fixed to the inner ring of the bearing, and the stator and rotor constitute a magnetoelectric conversion unit and are used to generate electricity by cutting magnetic field lines.

[0013] Preferably, the stator further includes a stator housing and a sealant. The stator housing provides mounting space for the PCB board, which is the core component of the stator. The PCB board integrates a magnetic yoke, induction coil, multi-parameter sensor, rectifier module, and signal transmission module. The PCB is composed of 1-3 substrates depending on different requirements, and the substrates are connected by wires.

[0014] Preferably, the rotor is mounted on both sides of the self-powered intelligent idler roller, and its outer diameter is closely fitted with the inside of the bearing housing and rotates with the bearing housing. More preferably, permanent magnets are evenly distributed around the rotor, and the polarity of the permanent magnets is arranged axially with the stator coils to form an alternating magnetic circuit; the permanent magnets are bonded to the rotor, and different specifications and quantities of permanent magnets are selected according to different operating conditions.

[0015] Compared with the prior art, the beneficial technical effects of the self-powered intelligent idler roller of this utility model are as follows:

[0016] 1. This utility model's self-powered intelligent idler roller requires neither additional cable power nor additional battery power; instead, it relies on its own power generation to power the detection system. This solves the problem of complex cable wiring, as well as the issues of insufficient continuous monitoring and frequent battery replacements associated with battery power.

[0017] 2. The multi-parameter sensor of this self-powered intelligent idler roller is directly installed inside the idler roller, reducing installation costs by more than 60%. The multi-parameter sensor detects direct data from the idler roller, ensuring accurate data monitoring without any loss. This invention overcomes the data distortion problem caused by indirect detection in existing technologies. This invention ensures a stable sampling frequency and continuous operation, achieving 24 / 7 real-time data acquisition.

[0018] 3. The self-powered intelligent idler roller of this utility model can monitor the operating data of the idler roller and analyze the potential faults and life prediction of the idler roller based on the data, so as to provide more reasonable suggestions for the replacement of the idler roller and avoid problems such as downtime due to failure or high costs of inventory retention.

[0019] 4. The sealant of the self-powered intelligent idler roller of this utility model replaces the sealing structure, which not only plays a sealing role, but also avoids the risk of failure caused by the exposure of the mechanical structure; the sealing structure avoids short circuits caused by dust and moisture, and is suitable for harsh working conditions such as mines and ports; traditional ordinary idler rollers can be directly optimized into intelligent idler rollers by changing the type of sealing components, without affecting the installation size and structure.

[0020] 5. This utility model features a self-powered intelligent idler roller with multi-parameter coordination. The induction coil module and multi-parameter sensors are integrated and share the same PCB. Vibration, temperature, and speed data are directly exchanged through an internal bus, supporting the fusion analysis of idler roller fault characteristics. Attached Figure Description

[0021] Figure 1 This is a positional relationship diagram of the self-powered intelligent idler roller according to this utility model;

[0022] Figure 2 This utility model relates to a self-powered intelligent idler roller. Figure 1 A schematic diagram of the structure of one-quarter of the part;

[0023] Figure 3 This is a stator structure diagram of the self-powered intelligent idler roller according to this utility model;

[0024] Figure 4 This is a rotor structure diagram of the self-powered intelligent idler roller according to this utility model.

[0025] Figure 5 This is a PCB board structure diagram of the self-powered intelligent idler roller according to this utility model.

[0026] Explanation of reference numerals in the attached figures:

[0027] 1. Roller; 2. Bearing housing; 3. Retaining ring; 4. Shaft elastic retaining ring; 5. Idler roller shaft; 6. Stator; 61. Stator housing; 62. PCB board; 621. Generator board; 622. Main board; 623. Temperature measuring board; 624. Magnetic guide ring; 63. Sealant; 7. Rotor; 71. Rotor housing; 72. Permanent magnet; 8. Bearing. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0029] It should also be noted that, for ease of description, only the parts relevant to the utility model are shown in the accompanying drawings. Unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0030] It should be noted that the concepts of "first" and "second" mentioned in this utility model are only used to distinguish different devices, modules or units, and are not used to limit the order of functions performed by these devices, modules or units or their interdependencies.

[0031] It should be noted that the terms "a" and "a plurality of" used in this utility model are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0032] This utility model discloses a self-powered intelligent idler roller, which includes a roller, an idler shaft, and bearings. A bearing seat is fixedly installed at each end inside the roller, and the bearing seats are fixed to the idler shaft via bearings. The bearing seats and retaining rings, together with the stator and rotor, form a labyrinth seal structure to block external impurities. A PCB board is embedded in the stator, integrating an induction coil, a rectifier module, a multi-parameter sensor, and a signal transmission module. The induction coil senses changes in the magnetic field and generates current. The signal transmission module is preferably a wireless transmission module to reduce the risk of failure caused by wiring. This utility model's self-powered system, through its integrated magneto-electric and sealed design, achieves efficient energy conversion and low-loss operation, solving the pain point of traditional solutions relying on external power supply or additional batteries. It combines three major advantages: real-time performance, reliability, and long lifespan, providing an innovative solution for intelligent monitoring of industrial equipment.

[0033] The self-powered intelligent idler roller of this utility model will now be described in detail with reference to the accompanying drawings.

[0034] like Figure 1 and Figure 2 As shown, a self-powered intelligent idler roller adopts a symmetrical structure, meaning that the structures at both ends are completely identical. It includes a roller 1, an idler shaft 5, and bearings 8. A bearing seat 2 is fixedly installed at each end inside the roller 1. The bearing seat 2 is fixed to the idler shaft 5 through the bearings 8. The bearings 8 are installed at both ends of the self-powered intelligent idler roller. The bearing seat 2 and retaining ring 3, together with the stator 6 and rotor 7, form a labyrinth seal structure to block external impurities. The retaining ring 3 is installed at both ends of the idler shaft 5. The shaft is secured in the slots at both ends of the idler shaft 5 by elastic retaining ring 4. The idler shaft 5 is installed inside the roller 1 and inside the bearing seat 2, and is fixed to the bearing seat 2 through the bearings 8. The stator 6 is installed at both ends of the idler roller and at both ends of the idler shaft 5 and is circumferentially fixed to the idler shaft 5. The rotor 7 is installed on both sides of the idler roller, and its outer diameter is tightly fitted inside the bearing seat 2 and rotates with the bearing seat 2. The stator 6 and rotor 7 form a labyrinth seal structure. The stator 6 has an embedded PCB board, which integrates an induction coil, a rectifier module, a multi-parameter sensor, and a signal transmission module.

[0035] In a preferred embodiment, each self-powered intelligent idler has one roller 1. Roller 1 is the main load-bearing component of the self-powered intelligent idler, directly contacting the conveyor belt and bearing the material load to support the conveyor belt's operation and reduce frictional resistance. Roller 1 is a hollow cylindrical design, made of metal or wear-resistant non-metal, with a wear-resistant rubber layer covering its surface to reduce friction and noise. The outer diameter of roller 1 is φ89-800mm, and its length is set according to the conveyor belt width. Roller 1 and bearing housing 2 together form the rotating components of the idler. Roller 1 and bearing housing 2 are connected and fixed by welding, interference fit, spinning, or other methods.

[0036] Each self-powered intelligent idler roller has two bearing housings 2. The bearing housings 2 are used to fix the position of the bearing 8, ensuring the coaxiality of the idler roller shaft 5 and the roller 1. The bearing housings 2 are fixed to the roller 1 by welding, interference fit, or spinning. The bearing housing 2 is shell-shaped, hollow inside to accommodate the labyrinth seal structure formed by the bearing 8, stator 6, and rotor 7. The bearing housing 2, together with the labyrinth seal structure formed by the stator 6 and rotor 7, blocks external impurities. The stator 6 and rotor 7 form the labyrinth seal structure. The rotor 7 is the moving ring of the labyrinth seal. The rotor 7 is fixed to the bearing housing 2 by interference fit or bonding, and rotates together with the roller 1. The stator 6 is the stationary ring of the labyrinth seal. The stator 6 is circumferentially fixed to the idler roller shaft 5, and the stator 6 and idler roller shaft 5 are stationary. The stator housing 61 of the stator 6 and the rotor housing 71 of the rotor 7 are typically made of engineering plastics.

[0037] Each self-powered intelligent idler roller has two retaining rings 3, which are installed at both ends of the idler roller shaft 5 and axially fitted with the stator 6 to restrict the axial movement of the stator 6, thereby restricting the axial displacement of the bearing 8 and preventing the bearing 8 from dislodging from the bearing housing 2 under load. The retaining rings 3 are made of materials such as carbon steel and stainless steel, and their inner diameter matches the clamping section of the stator 6. The retaining rings 3 increase the mating area for the axial positioning of the shaft elastic retaining rings 4.

[0038] Each self-powered intelligent idler roller has two axial elastic retaining rings 4. The axial elastic retaining rings 4 are used to fix the axial position of the idler roller shaft 5 and prevent the idler roller shaft 5 from moving during operation. The axial elastic retaining rings 4 are locked in the grooves at both ends of the idler roller shaft 5. The axial elastic retaining rings 4 are made of 65Mn steel and their specifications match the diameter of the idler roller shaft 5.

[0039] Each self-powered intelligent idler roller has one idler shaft 5, which serves as the core load-bearing component, supporting the static and dynamic loads of the entire idler roller structure. The idler shaft 5 is installed inside the roller 1 and inside the bearing housing 2, and is fixed to the bearing housing 2 by a bearing 8. That is, the inner wall of the bearing housing 2 is fixed to the outer ring of the bearing 8; the idler shaft 5 is fixed to the inner ring of the bearing 8. During operation, the idler shaft 5 remains stationary, therefore the inner ring of the bearing 8 does not rotate.

[0040] Each self-powered intelligent idler roller has two stators 6, which are installed at both ends of the roller. The stators 6 are also installed at both ends of the roller shaft 5 and are circumferentially fixed to the roller shaft 5. Since the roller shaft 5 is fixed and does not rotate during operation, the stators 6 also do not rotate. The stators 6 are pressed and fixed to the inner ring of the bearing 8, and the stators 6 and rotor 7 form a magnetoelectric conversion unit that generates electricity by cutting magnetic field lines. Both the rotor 7 and stators 6 adopt a labyrinth seal assembly type, forming a labyrinth seal structure to prevent external foreign objects from entering the roller. The stators 6 have a built-in PCB board that integrates an axial flux coil array, a rectifier module, and a signal processing unit, realizing power generation, rectification, sensing, signal processing, and transmission functions.

[0041] like Figure 3As shown, the stator 6 further includes a stator housing 61, a PCB board 62, and sealant 63. The stator housing 61 provides mounting space for the PCB board and also serves as a labyrinth seal. The stator housing 61 is made of engineering plastics or composite materials. The PCB board 62 is the core component of the stator 6 and is installed inside the stator housing 61. The PCB board 62 integrates an induction coil, multi-parameter sensors, a rectifier module, and a signal transmission module. Depending on the requirements, the PCB board 62 can be physically divided into one substrate, two substrates, or three substrates, with each substrate having different functions or all functions integrated onto a single physical board. The induction coil is used for power generation, various multi-parameter sensors are used to detect various data, the rectifier module is used to stabilize the output current and voltage of the generated power, and the signal transmission module is used to upload the detected data to the gateway. In a preferred embodiment, the coil output of the power generation unit is connected to the rectifier module; the sensing unit composed of various multi-parameter sensors includes an integrated triaxial accelerometer, a temperature sensor, and a wireless signal transmission module. The sealant 63 completely covers and adheres to the PCB board 62, which not only fixes the PCB board 62 but also prevents damage to the components on the PCB board 62 caused by vibration. In a preferred embodiment, the sealant 63 is preferably epoxy resin.

[0042] In a preferred embodiment, the PCB board 62 adopts a structure of 3 substrates, such as... Figure 5 As shown, the PCB board 62 further includes a power generation board 621, a main board 622, a temperature measuring board 623, and a magnetic ring 624. The power generation board 621 is positioned close to the permanent magnet 72 to reduce the power generation gap and thus eliminate arc generation; the main board 622 is mounted close to the sealant 63; the temperature measuring board 623 is positioned close to the inner ring end face of the bearing 8 to measure the temperature of the bearing 8 at a closer distance; the magnetic ring 624 is attached to the back of the power generation board 621, which not only ensures the magnetic circuit closure but also strengthens the magnetic flux and suppresses eddy currents; the magnetic ring 624 is designed with different numbers of layers depending on the requirements, and the magnetic ring 624 is generally made of high magnetic permeability materials such as pure iron or silicon steel sheets.

[0043] In a preferred embodiment, the induction coil is mounted on the generator board 621, and the integrated multi-parameter sensor, signal transmission module, antenna, and other components are mounted on the main board 622. The temperature measuring board 623 is a temperature measuring chip or a surface-mount temperature sensor. The rectifier module can be arranged on either the generator board 621 or the main board 622, and the three physical PCB boards 62 are connected as one unit by wires.

[0044] Each self-powered intelligent idler roller has two rotors 7, which are mounted on both sides of the roller. Their outer diameter is tightly fitted inside the bearing housing 2, and they rotate with the bearing housing 2. Because the bearing housing 2 and the roller 1 are completely fixed, the rotational speed of the self-powered intelligent idler roller is the rotational speed of the rotors 7. The rotors 7 rotate with the roller 1, generating electricity through the interaction of permanent magnets and coils in the stator 6. The rotors 7 and stator 6 form a labyrinth seal structure to prevent dust from entering.

[0045] like Figure 4 As shown, rotor 7 consists of rotor housing 71 and permanent magnets 72. The permanent magnets 72 are fixed to rotor housing 71 by adhesive bonding, and are evenly distributed along the circumference. The polarity of the permanent magnets is aligned with the axial direction of the stator coils to form an alternating magnetic circuit, ensuring maximum change in magnetic flux during rotation. Different numbers and specifications of permanent magnets 72 are selected depending on the idler roller model. Depending on the application, the permanent magnets 72 can be selected as circular cross-section magnets, rectangular cross-section magnets, or sector-shaped cross-section magnets.

[0046] The stator-rotor sealed power generation structure, consisting of stator 6 and rotor 7, features vibration monitoring, temperature monitoring, and speed calculation. It collects triaxial vibration data via a MEMS accelerometer integrated into the PCB; it measures the temperature in real-time by using a temperature sensor (or thermistor) embedded in the stator, which is in contact with the outer ring of the bearing; and it obtains the rotor speed, i.e., the roller speed of the idler roller, through the frequency of the magnetoelectric signal. This stator-rotor sealed power generation structure generates electricity through magnetoelectric coupling between the stator and rotor, eliminating external mechanical dependence and improving energy conversion efficiency. Vibration, temperature, and speed sensors are integrated within the sealed structure to achieve multi-parameter collaborative monitoring. After rotor 7 and stator 6 are fully assembled, the gap is automatically controlled, and a labyrinth seal structure prevents dust intrusion while reducing eddy current losses.

[0047] Each self-powered intelligent idler roller has two bearings 8, which are installed at both ends of the roller. The inner diameter of the bearing 8 is fixed to the roller shaft 5 and remains stationary; the outer diameter of the bearing 8 is fixed to the inner wall of the bearing housing 2 and rotates with the housing 2. Therefore, the rotational speed of the outer ring of the bearing 8 is the rotational speed of the self-powered intelligent idler roller. The bearing 8 is a deep groove ball bearing with a clearance of C4. The specific model needs to be selected based on the roller shaft 5. The bearing 8 supports the roller shaft 5 and reduces rotational friction; it also features a permanent self-lubricating design to extend maintenance intervals.

[0048] Explanation of the collaborative relationships among the various components in a self-powered intelligent idler roller:

[0049] (1) Power transmission: The rotation of roller 1 drives rotor 7 to rotate through conveyor belt. The permanent magnet and stator 6 coil generate electricity. The electrical energy is rectified by PCB and then used to power the sensor.

[0050] (2) Sealing protection: The bearing housing 2, together with the stator-rotor traveling seal, blocks dust;

[0051] (3) Load bearing: The idler shaft 5 is fixed by bearings 8 at both ends, and the elastic retaining ring 4 ensures axial positioning and withstands the pressure of the conveyor belt and the impact of materials.

[0052] The working principle of this invention is as follows: The roller sealing structure is reconstructed into an integrated magneto-electric conversion and sensing module, specifically including a stator-rotor sealed power generation unit and a multi-parameter sensing module. The conveyor belt drives the self-powered intelligent roller to rotate, which in turn drives the rotor to rotate at the same speed. The rotor's permanent magnet and the coil in the stator's PCB board generate electricity through axial cutting magnetic flux. The current generated by this axial cutting magnetic flux is rectified by the rectifier module and then stably and continuously supplies power to the multi-parameter sensors and signal transmission module in the PCB board. The rectifier circuit ensures voltage stability during sudden changes in circuit load.

[0053] To better achieve the above-mentioned objectives, the working method of the self-powered intelligent idler roller of this utility model includes the following steps:

[0054] Step S1: The conveyor belt drives the self-powered intelligent roller to rotate, which in turn drives the rotor to rotate at the same speed; in a specific embodiment, the speed of the self-powered intelligent roller is between 100 rpm and 800 rpm.

[0055] Step S2: The permanent magnet of the rotor and the coil in the PCB of the stator generate electricity by cutting magnetic flux axially; the permanent magnets evenly distributed around the rotor rotate with the roller, and the N / S poles of the permanent magnets periodically sweep across the PCB coil area of ​​the stator. Due to the alternating arrangement of the magnetic poles, each coil unit experiences a change in the direction of the magnetic field from positive to zero to negative when the rotor rotates, forming an alternating magnetic field with the PCB coil embedded in the stator, cutting magnetic field lines to generate electricity. The axial arrangement of the permanent magnets and the stator (6) coils forms a periodic change in magnetic flux, and according to Faraday's law of electromagnetic induction, an alternating electromotive force is generated in the coil.

[0056] Step S3: The current generated by the axial cutting magnetic flux is rectified by the rectifier module and then stably and continuously supplies power to the multi-parameter sensor and signal transmission module on the PCB board. The PCB board integrates a rectifier and voltage regulator circuit module, which converts the self-generated energy into DC power with stable voltage and current. The electrical energy is continuously supplied to the detection module (sensor module) and the signal transmission module, enabling the sensor and signal transmission module to work in real time. In a preferred embodiment, the generated DC power is preferentially used to power the sensor, and excess energy is stored in a capacitor to avoid energy waste.

[0057] Step S4: The rectifier circuit ensures voltage stability when the circuit load changes abruptly; the output voltage is dynamically adjusted according to the load demand to ensure stable operation of the sensor.

[0058] Step S5: Multi-parameter sensors monitor the operating data of the self-powered intelligent idler in real time; the multi-parameter sensors operate in real time based on self-powered electricity, and collect the operating status parameters of the self-powered intelligent idler synchronously or in time-sharing manner according to a preset sampling frequency, and perform parameter monitoring such as vibration monitoring, temperature monitoring and speed feedback, and perform data preprocessing.

[0059] Step S6: The signal transmitting module transmits the data monitored by the multi-parameter sensors to the receiving terminal to monitor the working status of the self-powered intelligent idler of the belt conveyor in real time; the signal transmitting module transmits the data monitored in real time by the sensor module in step S5 to the gateway through the wireless channel, and the gateway forwards it to the cloud server or local monitoring terminal to generate a health status report and early warning information of the self-powered intelligent idler.

[0060] In summary, the self-powered intelligent idler roller of this utility model can be applied to different types of idlers without being affected by changes in the specifications, dimensions, or connection methods of the idlers. For example, modifying the fixing method of the idler shaft, modifying the axial positioning method in the example such as the spring retaining ring, modifying the shape of the bearing seat, and modifying the shape of the rotor and stator, etc., will not cause the essence of the corresponding technical solution to deviate from the spirit and scope of the technical solutions of the various embodiments of this utility model.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A self-powered intelligent idler, characterized in that, The self-powered intelligent idler adopts a left-right symmetrical structure, which includes a roller (1), an idler shaft (5) and a bearing (8). A bearing seat (2) is fixedly installed at each end of the roller (1). The bearing seat (2) is fixed to the idler shaft (5) through the bearing (8). The bearing seat (2) and the retaining ring (3) together with the stator (6) and the rotor (7) form a labyrinth sealing structure to block external impurities. The stator (6) has an embedded PCB board (62). The PCB board (62) integrates an induction coil, a rectifier module, a multi-parameter sensor and a signal transmission module. The stator (6) is installed at both ends of the idler shaft (5) and fixed around the circumference of the idler shaft (5).

2. The self-powered intelligent idler roller according to claim 1, characterized in that, The roller (1) adopts a hollow cylindrical design. The outer diameter of the roller (1) is φ89mm-800mm. The length of the roller (1) is set according to the width of the conveyor.

3. The self-powered intelligent idler roller according to claim 1, characterized in that, The roller (1) and the bearing housing (2) together form the rotating parts of the idler roller. The roller (1) and the bearing housing (2) are connected and fixed by welding, interference fit or spinning.

4. The self-powered intelligent idler roller according to claim 3, characterized in that, The bearing housing (2) is used to fix the position of the bearing (8) and ensure that the roller shaft (5) and the roller (1) are coaxial.

5. The self-powered intelligent idler roller according to claim 1, characterized in that, The retaining ring (3) is installed at both ends of the idler roller shaft (5) and is used for axial fixation of the stator (6).

6. The self-powered intelligent idler roller according to claim 5, characterized in that, The roller shaft (5) is provided with a shaft elastic retaining ring (4) in the groove at both ends. The shaft elastic retaining ring (4) is made of 65Mn steel and the diameter of the shaft elastic retaining ring (4) matches the diameter of the roller shaft (5).

7. The self-powered intelligent idler roller according to claim 1, characterized in that, The stator (6) is pressed and fixed to the inner ring of the bearing (8). The stator (6) and the rotor (7) constitute a magnetoelectric conversion unit. The stator (6) is used to cut magnetic field lines to generate electricity.

8. The self-powered intelligent idler roller according to claim 1, characterized in that, The stator (6) further includes a stator housing (61) and sealant (63). The stator housing (61) provides mounting space for the PCB board (62). The PCB board (62) integrates a magnetic yoke, an induction coil, a multi-parameter sensor, a rectifier module, and a signal transmission module. The PCB board (62) is composed of 1-3 substrates depending on different requirements, and the substrates are connected by wires.

9. The self-powered intelligent idler roller according to claim 8, characterized in that, The rotor (7) is installed on both sides of the self-powered intelligent roller, and its outer diameter is closely fitted with the inside of the bearing seat (2) and rotates with the bearing seat (2).

10. The self-powered intelligent idler roller according to claim 9, characterized in that, The rotor (7) has circumferentially distributed permanent magnets (72), and the polarity of the permanent magnets is arranged with the axial direction of the stator coil to form an alternating magnetic circuit; The permanent magnet (72) is bonded to the rotor (7).

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