Conveyor roller support structure and installation for conveyor systems

Abstract

A roller support structure for supporting a conveyor belt of a troughing or endless conveyor, the roller support structure configured to support centre rollers (36,136), spaced wing rollers (38,138), optional intermediate rollers (137), the roller support structure including a unitary frame (11) having transversely spaced upright posts (12,16) connected by a primary transom (20) extending therebetween having roller shaft slots (26,28) with machined slot tolerances to receive respective roller shafts. Centre roller brackets can support dual parallel centre rollers offset relative to a shaft axis of the wing rollers. The intermediate rollers (137) can be within a forward and a rear maximum centre roller projection. A mounting arrangement can provide up to 6-degrees of freedom of mounting adjustment between foundation supporting the frame (11) and the upright supports (12,16). Mounting bracket positional adjustment six degrees of freedom by connection of legs (12, 16) to anchor bolt arrangements (40).

Description

CONVEYOR ROLLER SUPPORT STRUCTURE AND INSTALLATION FOR CONVEYOR SYSTEMSTECHNICAL FIELD

[0001] The present invention relates to conveyor roller support structures for use in troughing conveyor belt systems, and to troughing conveyor belt systems incorporating such roller support structures.

[0002] One or more forms of the present invention relates to arrangements for installation and / or configuration of roller support structures, such as idler roller frames, for conveyor systems including overland conveyor systems.

[0003] One or more forms of the present invention has been developed primarily for use in a conveyor system utilising an endless belt supported on conveyor rollers for transporting bulk pulverulent or particulate material, such as coal, ore, minerals and grain, and will be described herein with reference to such bulk materials.

[0004] Specific examples of bulk materials are mineral sands, iron ores, coal, mineral ores, cereals, woodchips, sand, gravel, clay, cement, ash, salt, chemicals, wheat, sugar, flour and stone in loose bulk form. It can also relate to the handling of mixed wastes in bulk volumes.

[0005] Conveyor systems applicable to the present invention are often referred to as ‘troughing conveyors’ (due to the concave ‘trough’ profile shape of the endless belt supported on the conveying idler rollers / rollers for conveying the bulk material) or simply Toller conveyors’ (referring to the rollers supporting the conveying belt) or ‘overland conveyors’ (referring to the physical cross-country extent of the lengthy conveyor). Such terminology and arrangements are encompassed within the scope of the present invention.

[0006] The rollers supporting the belt on the roller support structures of bulk material conveyors are often called idler rollers, or sometimes just idlers. Other terms are synonymous, such as conveyor idler rollers, conveyor rollers, or just rollers, relating to the cylindrical bodied rotatable rollers, which are all considered equivalent as each other for the purposes of this specification.BACKGROUND

[0007] Troughing conveyors typically have an endless belt driven over and supported by rollers in operation, the rollers typically arranged with centre and wing rollers supported transverse to the extent of the endless belt. A number of consecutive centre and wing roller arrangements are positioned at spaced intervals supporting the extent of the endless belt.

[0008] Roller support structure configurations (such as idler roller assemblies / modules) generally utilise inclined "wing" rollers either side of a centre roller at the base of the generally concave ‘U’ shape created by the rollers for the load carrying portion of the belt.

[0009] Offset rollers have been considered, such as five rollers per set (as opposed to the more conventional three idler roller per set configuration) wherein alternate rollers are arranged in a staggered pattern when viewed from above. Although the resulting shorter rollers may be made to allow smaller roller to be employed, and therefore lower rated roller bearings and seals, the load is still the greatest at the centre roller position and furthermore there can be inherent problems in matching belts to the profile of the staggered rollers in such arrangement, and nonetheless, many more rollers are required. Indentation friction losses still occur as the load carrying belt travelling over the rollers indents the belt bottom cover.

[0010] A conveyor roller is typically mounted to a support structure (such as a frame) having upright supports connected to longitudinal ‘stringer’ members. Aclad roof structure can be supported over the conveyor belt from the stringers and / or legs. The centre axle of the respective conveyor roller can be either connected via the roller support structure / frame to the leg or the stringer, allowing the roller’s cylindrical body to rotate on bearings about the axle. Typically independent of the support structure, these connections allow for in situ adjustment of the conveyor roller to supporting structure to achieve desired construction installation tolerances. Bracketry is normally required to achieve six degrees of freedom adjustment.

[0011] Load distribution of the bulk material load on the belt is concentrated on the centrally located conveyor rollers due to the nature of the surcharge angle of the bulk material being conveyed and the inclined angle of the wing rollers inclined upward and away from the respective central roller.

[0012] Typically, the load weight born by the central roller in a traditional equal length three roll offset or inline conveyor is between 70% and 80% with each outside wing roller respectively carrying only 15-10% of the load (central roller with an inclined wing rollers inline in a transverse plane relative to the longitudinal extent of the conveyor belt and stringers). Several ways have been tried, seeking to reduce individual roller loads and thus losses. These include implementing 4 and 5 roll configurations, reduced centre roller length / width (length of the roller body), centre roller diameters up to 219mm relative to wing rollers and changing the angle of wing roller inclination (steeper or shallower angle).

[0013] It will be appreciated that spacing between consecutive idler support arrangements along the length of the belt causes dips due to the load conveyed, resulting in cyclic pressure and recovery due to indentation within the belt bottom cover in conveying the load over the rollers. The indentation pressure distribution is asymmetric and the relaxation of this belt indentation after losing contact with the roller results in hysteresis, leading to increased conveying resistance (indentation rolling resistance (IRR)) and increased energy losses.

[0014] Additional losses within a conveyor system are attributable to roller labyrinth seal viscous drag, lip seal frictional resistance and rolling element bearing friction. Seal viscous drag losses are dependent on, and proportional to, angular velocity and outer seal radius. For a given belt speed, an increase in roller diameter will result in lower angular velocities. Lip seal resistance is dependent on and proportional to seal contact diameter and roller diameter. Rolling element bearing friction is dependent on, and proportional to, radial force. It has been realised that increasing the roller diameter with respect to the bearing and seal outer diameters aids reducing or minimising these losses.

[0015] A roller bearing is rated through the L10 life calculation, usually in accordance with an international standard such as ISO 281 :2007, Rolling bearings - dynamic load ratings and rating life. The L10 life of a bearing is a calculation providing within 90% reliability how many hours a bearing will last under a given load and speed. Thus, a 10% probability exists for the applied load and speed, that 10% of identical bearings would suffer a fatigue failure. Bearing raceway pitting is a common cause of bearing failure. For a given belt speed and burden load, an increase in idler diameter results in a reduction in the bearing size required due to the reduced rotational speed for a given life requirement. For example, a 1500mm wide conveyor belt travelling at 6m / s velocity and 100% CEMA rating requires a 6312 ball bearing for a 152 diameter roller but only a 6309 size ball bearing for a 508mm diameter idler. This is a reduction of the bearing outer diameter from 130mm to 100mm and inner diameter from 60mm to 45mm that the roller designer can use to implement a labyrinth seal design with a smaller outer seal diameter or a lip seal with smaller seal contact diameter.

[0016] US 2002 / 0050444 patent document to Tapp discloses a four-roll offset roller arrangement having two centre rollers of larger diameter than the wing rollers, with the centre roller paired on a pivot mechanism allowing a pair of pivot brackets that support each respective centre roller to rotate about a centre pivot shaft to equalize the load felt by each of the centre rollers and minimise energy losses. However, the pivot mechanism can seize or become worn and needs monitoring and maintenance additional to normal conveyor system components.Such a system has typically been deployed at belt spans between idler support frames to reduce the centre roll load to minimise IRR, but this creates a trade-off of increased capital expense for installation and perceived additional operating costs due having more components than a conventional 3 roll system.

[0017] Other dual centre roll arrangements have been contemplated, such as pivoting garland idlers (e.g. of a type published in WO2019183705A1 ), pivoting with dolly / rail carrier rather than stringer (e.g. as published in US 2004 / 0222071 A1 ), torsion spring mounted arms (such as published in US3757930A), and pivoting with removeable arm for changeover of roll configurations (such as published in JP2011255990A).

[0018] Traditional conveyor idler support structures (low-level and mid-level modules) have two sets of legs and a stringer structure, and may have cover cladding attached for dust mitigation and solar and weather protection. Known idler support structures are typically fixed to the stringers due to the configuration of the design lengths of the module in 6m, 7.5m, 8m, 9m, 10m and 12m lengths in conjunction with idler spans. The stringers also provide structural integrity to the conveyor system resisting the overturning moment imparted when bulk material is asymmetrically loaded on the belt across the idler frame lateral span. Aligning idler frames along the conveyor route is an arduous task on a construction site that requires multiple surveying alignment points.

[0019] Angular misalignment of the wing roller to the true belt line creates a transverse slip between belt and roller that imparts a transverse force, creating a retardation force to belt movement, that is seen as a tension and hence energy loss. When rollers are mounted to the stringer, the stringer will deform and physically displace under the burden load. The roller will also deform and physically displace.

[0020] In addition, for offset rollers typically used in overland conveyors, the wing roller is displaced relative to the transverse plane, effectively skewed, withthe mount positions moving relative to the longitudinal extent of the endless belt. Offset roller stringer mounting bracket designs can optimise the mounting position to reduce this displacement for a nominal design case, however the extent of displacement is dependent on the loads from the often-fluctuating burden.

[0021] Known ground module idler frame components for conveyor systems typically arrive at site requiring assembly. Normally this is performed in a laydown / assembly yard. The extent of any pre-assembly undertaken prior to transport will determine the level of connection / assembly of components on site. Land area, equipment, tooling and labour will vary depending on the extent of connection / assembly required. Depending on the accuracy desired and the tolerance stack of all components in the conveyor assembly (including module components, foundations and earthworks), a jig may be required for assembling the ground module. Multiple surveys both in the jig and on the construction site are typically required for the installation to achieve a tighter tolerance accuracy.

[0022] Alternatively, the ground module assembly (frame arranged to support rollers) may be built and then an in-situ survey method can be performed, such as stringline to check relative levels (RL) of rollers from one idler frame to the next, conveyor centrelines and squareness to the centreline. A conveyor system is typically set out in the field by adoption of survey work points, defining the conveyor centreline and Relative Level (RL) of the belt underside at the top of flat rolls (3 and 5 roll carry rollers and 2 roll flat returns) and intersection point on inclined idlers (like 2 roll vee and inverted vee return idlers). Easting and Northing positions for idler frames, foundations, anchor bolts are also defined and various survey methods such as chainage bars for anchor bolt location or survey prism and totalising station for anchor bolt nut RL are performed.

[0023] Typically, known idler support frames have a general fabrication tolerance of + / -2mm on X, Y, Z positioning in roller shaft slot locations. For such overland conveyors, where efficiency is desired, a tighter tolerance scheme may be specified by the designer. To fabricate an idler support frame to tight tolerance slot locations (i.e. + / -0.5mm) without machining subsequently requires very tighttolerancing on all components throughout the manufacturing processes; for example, the roller shaft slot may be cut into the profile of the fitting via laser cutting the plate. Without self-adjusting machines, the laser beams spread when cutting which results in a tapered kerf profile on the slot. If the plate requires bending, then it must be checked against jigging. To reduce waste, manufacturers will typically balance the time to achieve the dimension through reprocessing within an allowable tolerance band. Using a statistical process control method, fittings are grouped and will be assembled to optimise the fabricated dimensional outcome.

[0024] Welding and galvanising processes both impart heat into the metal during the manufacturing process of constructing known idler frames. In the case of welding, the high heat input contracts the welded materials pulling, them inwards. In a suspended idler support structure, such as the above, this process pulls brackets inwards towards themselves. In a galvanising bath the lower heat input will act to stress relieve and relax the material out from the welded position. Both processes affect the final positioning of the fabricated slot. Further processing through survey using coordinate measuring machine or jigging is required to ensure compliance with tolerance. Final machining post fabrication and surface treatment allows for a typical tolerance of + / -0.1 mm on X, Y, Z positioning in slot locations with quality control survey.

[0025] Vibration is a problem for bulk material conveyors. Vibration can be caused by the operation of the conveyor, by roller rotation, belt flap between idler frames / supports, bulk material load clumping, the wind, and other causes internal and external to the conveyor. If there is harmony of the load frequency and the belt flap or structural frequency, the vibration can have a catastrophic effect on the structure or operation of the conveyor. A way to minimise belt flap is to have irregular roller support structure / frame spacing along the length of the belt so that harmonics are disrupted.

[0026] It will be appreciated that overland conveyor systems are a large installation cost centre in terms of materials, fabrication, transport, site works andconstruction. In addition, operational costs include power use, power losses, belt wear / replacement and roller maintenance / replacement.

[0027] To minimise the quantity of material used in the structure, less material (steel) of a standard grade is cheaper than more such material or a more exotic grade of material.

[0028] Conventional overland conveyor ground modules have suspended rollers, fitted within the stringers, that often utilise a bent pipe structure as the supporting member and plate (either flat or bent) or modified hot rolled section for the roller mounting brackets. Typically, 3 offset roller and 5 offset roller supports have their rollers alternating either side of the bent pipe extending transverse relative to the belt.

[0029] Alternatively, overland conveyor ground modules (fitted to the top of stringers or brackets mounted to the legs) utilise a structural section design of hot rolled equal angle as the supporting member and plate (either flat or bent) for the roller mounting brackets or a bent pipe design. The rollers can be arranged directly inline or offset (alternating) along the support structure.

[0030] Translation and rotation installation tolerances for a single central roller on overland conveyors are typically + / -1 mm across belt (transverse i.e. across a conveying direction), + / -2 mm along belt (longitudinal i.e. inline with a conveying direction), + / - 1 mm RL (elevation) (1 mm elevation deviation between adjacent centre roll elevations, where more than 2 idlers are located on one ground module) and + / - 0.1 ° in yaw (e.g. horizontal angular rotation relative to a centreline) (measured at top and centre of the centre roll), + / - 0.1 ° in roll (measured at top of centre roll) and + / - 0.1 ° in tilt / pitch (measured at side of wing roll by placing a flat surface against the side of the roll).

[0031] Adjustment of the idler roller position to achieve tolerance is undertaken via manipulation of the idler roller with respect to the ground moduleframework it is supported within. After the ground module framework is removed from a preassembly jig (if used), an idler roller is usually not suported by anything other than friction between its mounting points / base plate and the receiving structure from the mounting bolts for any required adjustments. Shimming is often required within the bolted connection arrangement to achieve tolerance.

[0032] For known overland conveyor construction methods, final idler roller positioning can involve many of the following multiple survey points: survey of idler roller slot positions (in factory), ground elevation and superelevation at coordinates, set out diagonal corners to locate the sleeper, chainage between sleeper anchor bolts, anchor bolt Easting / Northing position and locking nut RL, survey of idler roller installed in ground module framework, digital spirit levels / straight edge across top of centre idler rollers, Easting / Northing and relative level (RL) of lead in and lead out idler roller on the ground module framework, laser elevations of idler rollers between lead in and lead out idler rollers, stringline / piano-wire of centre rollers (straight / flat section only) across multiple modules, clocking arm checks from stringline for squareness and lateral arm offset, stringline and plumb bob used for return idler roller centreline checks, ‘dumpys’ used to set RL on return rollers, measuring tape between idler rollers, laser scanning of centre roll location in curves (horizontal I vertical), laser scanning of top of each wing roller location in curves to confirm lateral offset and squareness. These methods are laborious, time consuming, inefficient, and often compromised as a direct result of, and due to, specified fabrication tolerances.

[0033] Slot positions in fabricated (not machined) idler frames for overland conveyors are usually in the range of + / -0.5 mm to + / -2 mm from specified positions. For wing roller outer slot positions, the tolerance range is usually offset downstream on conveyors, i.e. 0 / +1mm, to ensure that there is always a positive angle (towards the conveyor head) to attempt to ensure that the manufacturing tolerance never induces a transverse slip / skew load on the belt from either wing roller where the outside slot of the wing is closer to the tail than the central slot.

[0034] An extreme case of three roller carry idler fabrication tolerance error allowed in a + / -0.5mm tolerance scheme presented, is when the centre roll is - 0.5mm (towards the conveyor tail) nearest the wing where the outer slot is +1 mm (towards the conveyor head). This creates difficulty in field alignment and causes belt on idler alignment friction.

[0035] It is accordingly desirable of the present invention to ameliorate one or more difficulties associated with existing structures for overland / troughing conveyors, their associated idler / roller support structures / frames and / or idler / roller support structure / frame positioning and installation, or at least to provide the market with an alternative.

[0036] It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.SUMMARY

[0037] Embodiments includes an overland conveyor installation arrangement including a roller support structure for supporting a conveyor belt of a troughing or endless conveyor (such as on rollers). The roller support structure can be arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, wherein the support structure includes roller shaft slots with machined slot tolerances to receive the respective roller shafts.

[0038] Threaded fastener connection may be provided between the frame and a foundation having six degrees of freedom of adjustment. The threaded fastener connection may include an adjustment arrangement with at least one spherical or dished washer arrangement. The spherical or dished washer arrangement may provide fine roll and pitch adjustment for the frame.

[0039] Embodiments may include elevation adjustment by the positioning on at least one anchor bolt of the respective threaded fastener.

[0040] Embodiments may include one or more bevelled washers may provide coarse roll positioning, where the anchor bolt is designed vertical or through the sleeper being supported off terrain with superelevation.

[0041] An oversize hole or void through a baseplate may be provided for transverse, longitudinal and / or yaw adjustment. At least one plate washer may be dimensioned to cover the hole or void at all anchor bolt positions.

[0042] Embodiments may include at least one survey jig for coarse positioning of a preassembled foundation and the frame.

[0043] The at least one survey jig may include a dual satellite positioning system or GPS survey jig. Embodiments may include a dual optical prism survey jig positioned on the frame, with or without inertial measurement. Preferably, the respective survey jig mounts directly in the roller slots or on top of the rollers. Preferably the sensing elements (GPS, inertial measurement system, optical prisms, separate or in combination) are located at the zero-offset position within the survey jig relative to the conveyor and idler frame centrelines.

[0044] Embodiments may include rectangular survey accuracy dimensions of 1 mm in horizontal and vertical positions / axes. Yaw, pitch and roll angular offsets of 0.1 degrees with the optical prisms greater than 573mm apart.

[0045] Embodiments may include at least one stringer having a horizontal slot for bolted interface connection to the idler. Slot length can enable longitudinal adjustment required for the GPS and prism positioning accuracy.

[0046] A method for installation of a roller support structure for an overland conveyor system, the roller support structure for supporting a conveyor belt of atroughing or endless conveyor (such as supported on rollers), the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, wherein the support structure is preassembled with roller shaft slots having machined slot tolerances to receive the respective rollers / roller shafts.

[0047] Embodiments may include providing threaded fastener connection between the frame and a foundation having six degrees of freedom of adjustment. Embodiments may include enabling adjustment in the threaded fastener connection with at least one spherical or dished washer arrangement. The spherical or dished washer arrangement can be employed to provide fine roll and pitch adjustment for the frame. Elevation adjustment may be provided by positioning on at least one anchor bolt of the respective threaded fastener. Coarse roll positioning may be provided through bevelled washers, where the anchor bolt is designed vertical or through the sleeper being supported off terrain with superelevation. Transverse, longitudinal and / or yaw adjustment may be provided by an oversize hole or void through a baseplate. At least one plate washer may be provided dimensioned to cover the hole or void at all anchor bolt positions.

[0048] Embodiments may include mounting at least one survey jig for coarse positioning of a preassembled foundation and the frame. The at least one survey jig may include a dual satellite positioning system or GPS survey jig. The at least one survey jig may include providing a dual optical prism survey jig positioned on the frame, with or without inertial measurement. Embodiments may include mounting the respective survey jig in the roller / roller shaft slots or on top of the rollers or roller shafts.

[0049] Embodiments may include providing rectangular survey accuracy dimensions of 1 mm in horizontal and vertical positions / axes at one standarddeviation of uncertainty. Embodiments may include providing 0.1 degrees yaw, pitch and roll angular offsets with the optical prisms greater than 573mm apart.

[0050] Embodiments may include providing at least one stringer having a horizontal slot for bolted interface connection to the idler. The respective slot may have a slot length providing longitudinal adjustment required for the GPS and prism positioning accuracy.

[0051] With the aforementioned in mind, an aspect of the present invention provides a roller support structure for supporting a conveyor belt of a troughing or endless conveyor (such as on rollers), the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, the primary transom supporting centre roller brackets to support dual centre rollers, and first and second wing roller mounting brackets for supporting respective first and second spaced wing rollers either side laterally of the centre roller brackets, wherein the centre roller brackets are configured to support dual centre rollers offset relative to a shaft axis of the first and second wing rollers.

[0052] Embodiments include the upright supports have transversely spaced legs.

[0053] An outer end of a respective roller shaft of the first and second wing rollers may be supported on an inclined bracket attached directly to the respective one of the spaced upright posts such that the respective roller shaft is symmetrical about a principal axis of the respective upright post.

[0054] Embodiments include a secondary transom asymmetrical to and offset about the principal axis of the respective upright post. Embodiments having the secondary transom may include return roller brackets for supporting a return beltportion of the conveyor belt. The return roller brackets may support respective return rollers in a V, flat or inverted V configuration.

[0055] The one or more of the upright supports may be secured at a base thereof to a foundation. The foundation may include one or more of a sleeper, bored pier, slab, slab and pedestal, slip form paving or truss structure.

[0056] Embodiments may include a mounting arrangement providing six degrees of freedom of mounting adjustment between the foundation supporting the frame and the upright supports of the frame.

[0057] The roller support structure, mounting arrangement or superelevation of the earth pad under a sleeper or other foundation type (e.g. bored pier, slab, slab and pedestal, slip form paving or truss), may provide inclination adjustment, such as at the feet or base of the respective upright supports. The inclination adjustment may include the legs and carry rollers and return rollers which may tilt and / or height adjust to provide stabilising force on horizontal curves. Inclination adjustment can be in a transverse / lateral roll plane of the support structure / frame i.e. relative to a longitudinal conveying direction.

[0058] Tilt inclination adjustment may include at least one adjustment attachment position / point between the upright supports / legs of the frame and the secondary transom / return idler / roller support transom. Tilt inclination adjustment can be in a transverse / lateral roll plane of the support structure / frame i.e. relative to a longitudinal conveying direction. The tilt inclination adjustment may include a radial slot on one connection side / frame and holes on the other connection / secondary transom for adjustment within the desired arc transcribed by the fixing point from the centre of the top of the central roller at mid plane of the frame. The tilt inclination adjustment may include a number of horizontal slots or holes on one connection side / frame and upright / vertical slots or holes on the other connection / secondary transom, or vice versa, for discrete angular adjustability.

[0059] A respective outer extent of the wing roller and centre roller mounting brackets may be contained within an area, in plan view, of the foundation enabling offsite preassembly and optimised transportation nesting efficiencies within standard transportation dimensions of shipping containers and / or vehicles.

[0060] Location of the frame relative to the foundation may be adjustable by adaption of either or both of the upright supports or the foundation.

[0061] The foundation and / or the frame may include multiple channels aligned longitudinally with respect to the conveyor belt and / or twist lock dimensions or other arrangements that allow powered means of relocation. Such arrangements enable capture of the frame or the preassembled unit whilst positioning it in a manner to prevent uncontrolled movement.

[0062] One or more embodiments of the present invention relates to a conveyor roller support structure that supports the conveyor rollers in an arrangement to help at least one of: limit or control of indentation rolling resistance (IRR), minimise labyrinth seal, lip seal and / or bearing drag losses, within the conveyor system in operation.

[0063] Additionally, embodiments provide benefits of larger diameter rollers (larger than standard / commonly used idlers, preferably at least 152mm or larger) and the resulting slower rotational speeds are reduced noise impacts from deviations in instantaneous slope of the respective roller’s circumferential surface profile for a given Total Indicator Runout tolerance and increased roller shell wear life.

[0064] The primary transom may be integrally connected to the upright supports, which supports may be laterally / transversely spaced legs. The support for the at least two spaced centre rollers may be supported by the at least one integral transom.

[0065] The roller support structure may be fabricated from welded components. The roller support structure may be provided as a support module or frame. The support module or frame may be wholly or partially prefabricated, such as by welding, bolting or other fixing arrangement, or a combination of two or more thereof, such as for delivery and installation.

[0066] The roller support structure may be stackable or nestable. At least two said roller support structures may be configured to stack or nest at least partially together, such as for transport prior to installation. A plurality of the roller support structures may be so stacked / nested together for transport or storage prior to installation / ground G mounting.

[0067] The centre roller brackets for the at least two centre rollers may be configured to support centre rollers of between around 152mm to around 711 mm diameter.

[0068] The idler support structure may be arranged and configured to accommodate rollers that have roller diameter to bearing and seal outer diameter ratios greater than 1 :1 , optionally 4 or 5:1 , or up to a maximum of 7:1 , or a combination of two or more thereof providing larger diameter centre roller(s) with respect to smaller diameter wing rollers.

[0069] A further aspect of the present invention provides a troughing or endless conveyor system, such as a conveyor belt supported on rollers, including at least one embodiment of the aforementioned conveyor roller support structure.

[0070] Embodiments of the system may include spacing between said roller support structures supported by the ground G of between 12m and 13.5m. The system may include 6m to 6.75m spacing between upright posts of the respective roller support structures.

[0071] Tolerancing for supporting rollers in the roller support structure may include fabrication tolerances of + / -2mm for welded frame components in conjunction with machined mounting bracket slots that provide roller axis squareness relative to a conveyor centreline (CLc).

[0072] Mounting bracket positional adjustment in six degrees of freedom may be via the connection of at least two anchor bolts.

[0073] The roller support structure may include the at least one centre roller and / or the at least one said wing roller as a pre-assembled module. Alternatively, the roller support structure be preconstructed and the respective idler(s) subsequently added during or after installation of the roller support structure onsite.

[0074] The roller support structure may be pre-assembled with a sleeper and / or with or without rollers, for an optimised transportation arrangement. The roller support structure may include at least one roller slot bracket for supporting / receiving at least a portion of at least one said centre roller (such as to support an axle or bearing(s) of the respective idler) within the footprint.

[0075] One or more embodiments of the roller support structure need not include or be connected to a stringer to support the respective rollers.

[0076] The roller support structure may include a transom integrated transversely between the upright support (e.g. vertical post type legs) on a first side of the structure and the respective upright support on a second, transversely opposite side with respect to the conveying direction of the conveyor system.

[0077] One or more embodiments of the roller support structure may be configured having a ‘goalpost’ type leg structure, optionally including support for one or more return rollers as well as support for the central and wing carry rollers.

[0078] Carry refers to the direction carrying material on the belt. Return refers to the return portion of the belt (underneath the carry portion of the belt).

[0079] One or more embodiments of the roller support structure may include multiple ground module structures being nestable (one within another) for transport. Furthermore, stackable or flat-packed transportation of one or more connection members and / or cladding may be provided. Rollers may be crated or supplied mounted within the module(s).

[0080] One or more embodiments of the roller support structure may be provided as a module, which may be symmetric about the carry wing rollers, optionally with a return roller mount / bracket provided on at least one said leg.

[0081] It will be appreciated that one or more embodiments of the present invention may provide differences in the span between return rollers of consecutive modules / arrangements that enables a reduction in potential harmonic belt flap vibrations in the return portion of the belt.

[0082] It will further be appreciated that one or more embodiments of the present invention may provide differences in the span between the carry rollers (centre and wing) of consecutive modules / arrangements that enables a reduction in potential harmonics in the carry portion of the belt.

[0083] One or more embodiments of the roller support structure may include an upper support and a lower support for at least first wing roller, preferably for respective first and second opposed wing rollers.

[0084] A roller support structure according to one or more embodiments may include wing rollers inclined between 10 degrees and 45 degrees, such as 10, 15, 20, 25, 30, 35, 40, 45 or 55 degrees respectively, optionally with such rollers that are greater than 152mm (~6 inch) and up to 711 mm (~28 inch) diameter.

[0085] For one or more embodiments of the roller support structure, the centre and wing roller length dimension(s) can be either equal or unequal.

[0086] For one or more embodiments of the roller support structure, the centre and wing roller diameter dimension(s) can be either equal or unequal.

[0087] Embodiments may include: a 3-roller inline or offset configuration, or a 4-roller (double centre rollers) or 5-roller offset configurations.

[0088] Embodiments can include a span between consecutive roller supports / frames along the conveyor of 2m, preferably around between 6m to 6.75m.

[0089] Utilising both the system of National Standards for vehicles know as ADRs (Australian Design Rules) and ISO 668 - Series 1 freight containers — Classification, dimensions and ratings as a basis, a roller support / frame span of 6m and 6.75m is desired to enable optimisation for both road and sea transportation of the stringer. 12m (40ft) and 13.5m (45ft) are the maximum intermodal container internal dimensions as well as the maximum trailer lengths.

[0090] A further aspect of the present invention provides a roller support structure for use in supporting a conveyor belt of a troughed belt conveyor, the structure including: a support frame having a vertical / goalpost leg structure.

[0091] Centre roller mounting brackets may extend between / from transom members. Preferably, a first and a second centre roller are supported by centre roller mounting brackets.

[0092] Embodiments include a support frame, preferably with dimensions for mounting bracket slot axis offsets between wing rollers, centre rollers, intermediate rollers, and transoms, that accommodate rollers that have roller diameter to bearing or seal outer diameter ratios greater than 2:1 (i.e. 152mm or178mm diameter idlers) and preferably 4 or 5:1 . (i.e. 406mm or 508mm diameter idlers) up to a practical maximum of 7:1 (711 mm idler diameter) or a combination thereof, i.e. larger centre idler(s) and smaller wing rollers.

[0093] Roller diameters may be between around 152mm to around 711 mm. Spacing between modules on the ground G may be between 12m and 13.5m (equivalent to 6-6.75m between support legs).

[0094] Embodiments may include tolerancing on idler support structure components (shell face width and shaft length, shaft mounting slots) that accommodates fabrication tolerances of + / -2mm for welded frame components in conjunction with machined mounting bracket slots that present high accuracy roller axis squareness relative to the conveyor centreline whereby when combined with the use of a high accuracy survey jig allows for manual, semiautomated or automated machine-controlled installation. Mounting bracket positional adjustment in six degrees of freedom is via the connection of the anchor bolt(s) located on each leg of the module.

[0095] Embodiments may include a conveyor roller support system for a conveyor system. The conveyor roller support system may include at least two roller support structures, the roller support structures arranged with at least one stringer connecting between upright members.

[0096] Embodiments of the conveyor roller support system may include at least one of: roof cladding, belt drift switch, siren, light, control panel, pull wire / lanyard switches or pull wire / lanyard support brackets fixed to the respective stringer, or a combination of any two or more thereof.

[0097] Embodiments of the conveyor roller support system may include a module, wherein dimension between a conveyor pull wire / lanyard location and a bottom of the stringer is such that carry idler rollers are removable unencumbered by interference with the conveyor pull wire / lanyard and the stringer.

[0098] One or more of respective carry idler rollers may be automatically, manually, or partially manually removable via an assisted lift / zero gravity balance arm or robotic arm, including those proximal to a conveyor personnel cross over.

[0099] One or more embodiments may include at least a pair of the centre rollers arranged one leading / forward and one trailing / rearward with respect to a direction of travel of the conveyor belt, at least one pair of intermediate rollers, and the wing rollers, the centre rollers and the intermediate rollers being between the spaced wing rollers, wherein the centre rollers are spaced longitudinally from one another relative to the direction of travel of the conveyor belt such that the intermediate rollers are within a maximum forward projection of the forward centre roller and a maximum rearward projection of the rearmost centre roller. Pairs of said intermediate rollers, each of said pairs of intermediate rollers provided either side of the centre rollers with respect to a transverse direction of the conveyor belt.

[0100] One or more embodiments may include a conveyor installation arrangement including a roller support structure for supporting a conveyor belt of a troughing or endless conveyor, the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a unitary welded frame having transversely spaced upright posts connected by a primary transom extending therebetween. Preferably, the support structure includes roller shaft slots with machined slot tolerances to receive the respective roller shafts. Preferably the unitary frame includes a secondary transom to support return idlers / rollers. Preferably the frame includes pre-aligned slots to support respective ends of carry and / or return rollers.BRIEF DESCRIPTION OF THE FIGURES

[0101] One or more embodiments or examples of the present invention will hereinafter be described with reference to the accompanying Figures, in which:

[0102] Figures 1 A to 1 C shows respective front, side and plan views of conveyor roller support structure / frame (rollers not fitted) according to an embodiment of the present invention.

[0103] Figure 2 shows a perspective view of a section of conveyor system incorporating conveyor roller support structures according to an embodiment of the present invention.

[0104] Figure 3 shows the diagrammatic view (side view) by way of example of an embodiment of the present invention (rollers not installed).

[0105] Figure 4A shows an example of an adjustment arrangement for adjusting upright support position relative to a foundation, according to an embodiment of the present invention.

[0106] Figures 4B and 4C show examples of adjustability for upright support position relative to a foundation, according to one or more embodiments of the present invention. Figure 4B shows a general arrangement for range of adjustability of a support frame and Figure 4C shows detail of adjustability for the base / foot end of an upright of the support frame, according to one or mor embodiments of the present invention.

[0107] Figure 5A1 shows a chart of predicted modification factors for indentation rolling resistance due to horizontal conveying for various conveyor idler roller diameters.

[0108] Figures 5A2, 5A3 and 5A4 show respective charts of test data for large scale testing to AS 1334.13:2017 conducted at The University of Newcastle Research Associates (TUNRA) under particular parameters for relative force due to horizontal conveying versus temperature (T (°C)) for various conveyor idler roller diameters, according to embodiments of the present invention. Figures 5A2 to 5A3 contain IRR components only with belt flexure resistance accounted forthrough removal. Figure 5A4 incorporates a comparison of relative horizontal force against a CQ-N model prediction at 20 degrees Celsius.

[0109] Figure 5B shows a chart of relative roller labyrinth seal viscous drag diameter relationship according to embodiments of the present invention.

[0110] Figure 5C shows a chart of relative force due to horizontal conveying versus belt load for various conveyor idler roller diameters, according to an embodiment of the present invention.

[0111] Figures 6A to 6C show examples of Belt and Bulk Material flexure losses (e.g. due to belt opening and closing). Increasing idler span between roller sets reduces the flexure losses due to having fewer idler rollers, according to an embodiment of the present invention. Figures 6D1 and 6D2 show examples relating to contact pressure, and therefore belt stress at the belt and idler roll interface, particularly under the belt cords in steel cord belting and in the idler junction locations, and relatively larger diameter rollers reducing contract pressure, belt stress and consequently IRR, according to one or more embodiments of the present invention.

[0112] Figure 7 shows an example of idler roller junction (offset centre roller (CR) and wing roller (WR) junction region (JR)) according to an embodiment of the present invention.

[0113] Figures 8A to 8D show examples of conveyor systems incorporating embodiments of the present invention including pull wire / lanyard wire, auxi lliary control panels, midspan pull wire / lanyard wire support brackets, and belt drift switches.

[0114] Figures 9A1 to 9A3 show a belt lifting arrangement that supports the carry roller installation / removal / handling according to one or more embodiments of the present invention.

[0115] Figures 9B1 to 9B3 show features of the belt lifting arrangement of Figures 9A1 to 9A3.

[0116] Figures 10A, 10B, 10C1 and 10C2 show a belt lifting arrangement that supports the return roller installation / removal / handling according to one or more embodiments of the present invention.

[0117] Figures 11 A to 11 E5 show various foundation types for incorporation in one or more embodiments of the present invention.

[0118] Figures 12A to 12D show truss mounting positions according to various embodiments of the present invention.

[0119] Figures 13A1 to 13F2 show alternative configurations of lifting arrangements, according to embodiments of the present invention.

[0120] Figures 14A to 14E show packing and transportation arrangements according to embodiments of the present invention.

[0121] Figure 15 show installation survey jig arrangements according to embodiments of the present invention.

[0122] Figure 16 show roller lift assist arrangements according to embodiments of the present invention.

[0123] Figures 17A1 to 17A3 shows conveyor walkway cross over arrangements according to embodiments of the present invention.

[0124] Figure 18A shows an example of the tilt angle alpha (a) for carry roller referenced to a horizontal plane and the angle beta ([3) for the return roller referenced to a plane central to the carry roller (shown as vertical), according to one or more embodiments of the present invention. It will be appreciated that tiltand adjustment can be in a transverse / lateral roll plane of the support structure / frame i.e. relative to a longitudinal conveying direction.

[0125] Figure 18B shows an example of arc of rotation for [3 tilt angle for the secondary transom / return roller orientation according to an embodiment of the present invention.

[0126] Figure 18C shows an example for adjustable / positionable attachment between the upright supports / legs of the frame and the secondary transom (return idler / roller support transom) according to an embodiment of the present invention.

[0127] Figure 18D shows an alternative example for adjustable / positionable attachment between the upright supports / legs of the frame and the secondary transom (return idler / roller support transom) according to an embodiment of the present invention.

[0128] Figure 19 shows an example of an adjustment arrangement for six directional degrees of freedom of movement / adjustment for adjusting upright support position relative to a foundation, according to an embodiment of the present invention (Refer also to Figure 4A).

[0129] Figure 20A and 20B show an example a baseplate with oversize aperture and spacer allowing for transverse, longitudinal and yaw adjustment according to an embodiment of the present invention.

[0130] Figures 21 A to 21 C show features of spherical washer arrangements for use within bolted connection allowing for fine roll and pitch adjustment, according to at least one embodiment of the present invention.

[0131] Figures 22A to 22D show an example of a survey jig mounted in position on a support frame according to an embodiment of the present invention.

[0132] Figure 23 shows an example of rectangular prism survey accuracy according to an embodiment of the present invention.

[0133] Figures 24A to 24D show an example of a survey jig mounted in position on a support frame according to an embodiment of the present invention.

[0134] Figure 25 shows an example of rectangular survey accuracy dimensions in horizontal and vertical positions according to an embodiment of the present invention.

[0135] Figure 26A to 26B shows an example of achieving rectangular cube survey accuracy dimension 1 mm in horizontal, vertical and distance positions at >573mm offset between optical prisms for tolerancing on translation and rotation through the tolerance stack, according to an embodiment of the present invention.

[0136] Figure 27 shows an example of a horizontal slot for bolted interface connection between a stringer and a support frame / idler frame according to an embodiment of the present invention.

[0137] Figure 28 shows an example of an end detail of a roller shaft for orienting and positioning the roller shaft slots for installation of the roller into the idler frame bracket slots, according to an embodiment of the present invention.

[0138] Figure 29 shows an example of the practical geometry of accessibility to the roller shaft end detail with the use of larger roller diameters, according to an embodiment of the present invention.

[0139] Figures 30A to 30E show typical installation tolerances + / -1 mm across belt (Transverse), +1-2 mm along belt (Longitudinal), + / - 1 mm RL (Elevation) and 1 mm elevation deviation between adjacent centre roll elevations (where more than 2 idlers are located on one ground module), + / - 0.1 ° in Yaw (measured at top and centre of the centre roll), + / - 0.1 ° in Roll (measured at top of centre roll), + / -0.1 ° in Tilt I Pitch (measured at side of wing roll by placing a flat surface against the side of the roll).

[0140] Figures 31 A to 31 F show features of at least one embodiment of the present invention for multiple (e.g. 508mm (20”) diameter x8) offset carry rollers at 22.5 / 55° inclination and multiple (e.g. 178mm (7”) diameter x2) return rollers configured in an inline vee (with standoff mounting to transverse frame neutral axis).

[0141] Figures 32A to 32F show features of at least one embodiment of the present invention for eight 508mm (20”) offset carry rollers at 22.5 / 55° inclination and two 406mm (16”) inline vee return rollers with the return transom mounting inline to transverse frame neutral axis. Mounting returns inline to transverse frame changes where moment loads are applied.

[0142] Figures 33A to 33H show features of at least one embodiment of the present invention for four 508mm (20”) offset carry rollers at 45° inclination and three 406mm (16”) offset return rollers at 25° inclination with the return transom mounting inline to frame transverse neutral axis. The return transom can be independent or integral to structure in embodiments.

[0143] Figures 34A to 34G show features of at least one embodiment of the present invention with 508mm (20”) x6 offset carry at 22.5 & 45° inclination & 406mm 16”) x3 offset return at 25° inclination (mounting inline to frame transverse neutral axis). This embodiment is designed to reduce belt and bulk flexure losses on the carry profile. Survey jig would be mounted across two central rollers slots on each side.DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0144] In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. Theillustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised, and other changes may be made without departing from the spirit or scope of the subject matter presented.

[0145] It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

[0146] Embodiments provide for fabrication optimisation - enabling refinement of the process of fabrication and reducing fabrication costs e.g. typically cutting, bending, welding and machining time, use of consumables, labour, surface treatments and Quality Control (QC) (non-destructive testing and tolerances surveys). Plate, hot and cold rolled sections are preferably manufactured with individual tolerancing scheme which influences the manufacturer processing. For instance, plate which under 12mm thickness will typically come in coil form, may not be truly flat at the onset of processing. Circular Hollow Section (CHS) or Angle may have a bow or bend along the length. Typically, rollers (idler rollers) have a general fabrication tolerance of + / - 2mm on X, Y, Z positioning in slot locations on roller mounting brackets for mounting the roller shaft of the respective roller. For overland conveyors where efficiency is desired, a tighter tolerance scheme may be specified by the designer. To fabricate an idler frame to tight tolerance slot locations (i.e., + / - 0.5mm) without machining subsequently requires very tight tolerancing on all components throughout the processes. For example, the roller shaft slot may be cut into the profile of the fitting via laser cutting the plate. Without self-adjusting machines the laser beams spread when cutting, which results in a tapered kerf profile on the slot. If the plate requires bending, then it must be checked against jigging. To reduce waste manufacturers typically balance the time to achieve the dimension through reprocessing within an allowable tolerance band. Using a statistical process control method, fittings are grouped and will be assembled together to optimise the outcome.

[0147] Welding and galvanising processes both impart heat into the metal. In the case of welding the high heat input contracts the welded materials pulling it inwards. In a suspended idler, such as the above, this process pulls roller mounting brackets inwards towards themselves. In a galvanising bath the lower heat input will act to stress relieve and relax the material out from the welded position. Both processes affect the final positioning of the fabricated slot. Further processing through survey using coordinate measuring machine or jigging is required to ensure compliance with tolerance. In developing a new design often a number of sacrificial parts are prototyped and scrapped in an artisanal approach to refining these processes. Machining post fabrication and surface treatment, allows for a typical tolerance of + / -0.1 mm on X, Y, Z positioning in slot locations with quality control survey through on board CMM (Coordinate Measuring Machine).

[0148] Embodiments of the present invention provide frame 11 and roller 36, 38, 50 design and construction tolerancing arrangement that allows for the fabrication variations (typically 2mm) and high precision machining of slots (+ / - 0.1 mm), post fabrication, systematically reducing both wastage and time for each step in the fabrication. The tolerancing arrangement between assembly components of the roller shaft slot 26.1 , 28.1 and roll face widths and the receiving roller mounting bracket 26, 28 allows for the difference in fabrication and machining tolerances.

[0149] Embodiments of the present invention include a roller support structure 10 (‘the structure’), which may include a modular or frame structure 11 , that integrates carry and return roller support brackets 14, 18, 26, 28, 32, 34, such as at least one roller slot bracket 14, 18, at least one support structure / bracket 26, 28 and / or at least one return idler bracket 32, 34, within the footprint of the roller support structure (such as the module or frame). Return roller support brackets 32, 34 may be provided on a secondary transom 30. Embodiments of the structure can be symmetric about spaced carry wing rollers 38 spaced end on relative to one another transversely relative to the conveyor belt. Preferably, an outboard end of at least one said return roller 50 preferably both return rollers, ismounted to a bracket on a respective said upright support 12, 16, such as a leg of the structure.

[0150] Embodiments of the roller support structure 10, such as provided as a module embodiment, can alternatively be installed onto a poured / slip / moulded form, slab, slab and pedestal, concrete pier foundation or within a truss structure concrete foundation to create a concrete foundation member 42. A slip form concrete foundation member allows the overturning moments to be reacted by anchor bolts inserted into the continuous concrete mass, rather than at the interface between the earth and the bottom edge of the foundation in discrete sleeper type foundations.

[0151] One or more embodiments includes a dual centre roller 36 support structure / brackets 26, 28 that has an increased offset / spacing between adjacent centre rollers 36 (as shown by way of example in Figure 1 ), that is more akin to a conventional span between idler structure sets. Localised adjustment of roller height through machining the roller slots 28.1 , 28.2, 26.1 and 26.2 can be performed to allow for any uneven pressure distributions between fore and aft centre rollers 36. An integral primary transom 20 provides a stiff connection between the transverse spaced upright supports 12, 16 that is better able to resist bending and / or rotational moments. The primary transom 20 may include substantially parallel beams or a single beam, plates or other members (e.g. fabricated or cut or stamped) for additional stiffness resisting twisting / warp forces. The secondary transom 30 for supporting the return roller(s) can be forwardly or rearwardly offset from and below the primary transom. The secondary transom can have a V-shape, U-shape (V or U shape can be inverted) or can be horizontal. The return roller(s) can be suspended below the secondary transom such that the return portion of the belt travels over the return roller(s) and under the secondary transom.

[0152] As previously mentioned above, typical 3 and 5 roller overland conveyor ground frames with suspended rollers (fitted within the stringers) often utilise a bent pipe design as the supporting member and plate (either flat or bent)for the idler support brackets. Alternatively, typical overland conveyor idler frames (fitted to the top of stringers or on brackets within the legs) utilise a structural section design, e.g. hot rolled equal angle, as the supporting member and plate, either flat or bent) for the idler support brackets. Plate, hot and cold rolled sections are all typically manufactured with individual tolerancing schemes which influences the manufacturing process e.g., plate under 12mm thickness will typically come in coil form, may not be truly flat at the onset of processing, whilst circular hollow section or angle may have a bow or bend along the length. Embodiments of the present invention can utilise a modular support frame and idler tolerancing process / methodology that enables fabrication variations (typically + / -2mm) and high precision machining of slots (+ / -0.1mm), post fabrication, reducing both wastage and time for each step in the fabrication of the conveyor idler support structure. One or more embodiments of the present invention may include tolerancing for the support structure supporting rollers (such as shell face width and shaft length, shaft mounting slots) providing general fabrication tolerances of + / -2mm for welded frame components in conjunction with machined mounting bracket slots that present high accuracy roller axis squareness relative to a conveyor centreline. Mounting bracket positional adjustment in six degrees of freedom is via the connection of legs 12, 16 to anchor bolt arrangements 40.

[0153] Embodiments of the present invention provide a conveyor roller support structure 10 having a support frame 11 including upright or vertical transversely spaced support legs 12, 16 interconnected by a primary transom 20. The support frame 10 preferably incorporates both carry and return roller support brackets 14, 18, 26, 28, 32, 34 for mounting respective carry 36, 38 and return 50 rollers for rotation about respective roller axles thereof. This allows for combined module frame / leg and foundation (such as a concrete sleeper / member) transportation efficiencies as the entire structure can be assembled and fully dressed with guide rolls 58 and pull wire 54 pigtails 56 offsite with 6 degrees of freedom adjustment undertaken locally via the foundation 42 anchor bolt arrangement 40. Bevelled washers 74 (top and bottom of flat washers or in lieu of) allow for lateral angular tilt / camber of the frame to suit conveyor horizontal curve. Spherical washer sets 64U (upper), 64L (lower), allow / cater for someangular misalignment between the frame 11 and anchor bolt 72 of the respective anchor bolt arrangement 40 in pitch, roll and yaw rotation. An oversize diameter hole 68.1 through the baseplate 68 allows for frame 11 surge and sway planar translation. Nuts 70 and anchor bolt 72 allow frame 11 heave translation and fixing rigidity of the mounting / joint 40. Flat washers 74 (top and bottom) provide seal for grout containment.

[0154] For other foundation types, i.e. bored piles, slab, slab and pedestal and slip form concrete the units can be transported in a stackable or flat packed approach or pre-mounted and aligned within trusses.

[0155] Bulk solid flexure resistance occurs between successive idler sets as the bulk solid undergoes transverse and longitudinal displacement due to belt sag. As the belt progresses from one idler set to the next, Figure 6A idler sets A - E, the bulk solid undergoes cyclic expansion and contraction in the transverse direction, in addition to variation in height in the longitudinal direction. Transverse active and passive stress states are formed within the bulk solid as the belt opens and closes between successive idler sets Such relative movement results in energy losses due to the internal friction of the bulk solid. It has been realised that increasing idler span between roller sets reduces the flexure losses due to having fewer idler rollers. Access to, or use of, transportation trailers at mine sites without working at heights fall prevention arrangements or trailer access platforms is not permitted.

[0156] Embodiments of the present invention can include pre-formed notch or block-out holes in the concrete, additional fixtures on the steel work to constrain Industrial Truck Association (ITA) forklift tine mount classes (typically class II and III for the weight range considered) or a cut-out in the steelwork dimensionally similar to intermodal container ISO 1161 twist lock corner holes or other arrangements to allow for a captured and controlled removal of the assembly from the trailer without the use of ‘swiftlift’ anchors and rigging equipment that requires a dogman.

[0157] Embodiments can include the frame 11 having frame openings / cutouts to receive lifting apparatus, such as to isotainer ISO 1611 corner stadium or shield hole 76 dimensioned for side twist lock lifting (elevation and isometric) - see, for example, Figures 13C1 and 13C2. Alternatively, or in addition, the frame can include isotainer corner ISO 1611 cutout to stacking hole 78 dimensioned for vertical twist lock lifting (see, for example, Figures D1 and 13D2). Embodiments can include the frame 11 having external mounted forklift tyne / tine pockets 80, such as welded / bolted on pockets (see, for example, Figures 13E1 and 13E2) and / or can include internal forklift tyne / tine pockets / slots or channels 82 (such as integral to a transom or other cross-member (see, for example, figures 13F1 and 13F2).

[0158] Figures 14A to 14E represent embodiments including transportation options. Embodiments may include either a stackable or flat packed arrangement for transportation of the horizontal members 84 (e.g. Figure 14C) and cladding / roofing 86, optionally with brackets / longitudinal supports 88, (e.g. Figures 14D1 , 14D2 and 14D3) with crate or transport frame stacked / packed rollers 36 (e.g. Figure 14E) is proposed to complete the modules assembly. Module (frame) lengths, based on roller spacing, and therefore the horizontal members, can be configured around transportation length limits and design rules. Horizontal members 84, such as stringers, purlins or cable tray can be configured around transport length. Internationally the intermodal container system uses 40” (12m) and 45” (13.5m) containers. Frame spacing (ground module spacing) can be arranged and configured to utilise horizontal member lengths for transport in standard containers (horizontal members can be fixed to two legs (as indicated in Figure 2) or three legs. Integration of the roller mounting brackets of the frame (e.g. ground module), as opposed to within an independent idler frame that is then fitted to a ground module (on stringer or legs), enables a much more efficient construction process. A roller support structure 10 including the frame 11 premounted to the foundation 42 (such as a concrete sleeper or other member), can be taken off a truck, installed directly onto the prepared base, position utilising a GPS receiver 91 and stabilised.

[0159] Embodiments can include a survey jig 90 for use in establishing frame 11 position / orientation. The survey jig may include use of at least one, preferably at least two, prisms 92. For example, once the foundation is stable, a survey of centreline, RL and Easting and Northing coordinates can be performed once through the survey prism(s) 92 mounted on the survey jig 90 (preferably including a totalising station). Adjustments can be made in-situ until the final position is achieved. Anchor bolts can be locked onto the bases of the upright supports (such as feet of upright posts), such as with oversized washers and I or conical I spherical washers and nuts and the adjustment clearance void can be filled with grout to prevent movement.

[0160] For horizontal curves, belt tension tends to pull the belt towards the centre of radius, gravity action occurs on the belt, and material and friction at the interaction of contact between belt and roller, all impose a horizontal motivating force. To counteract this, and provide a stabilising force, rollers are tilted. Because the belt carry strand has the material and the return strand has not, and due to the carry side often having different tensions than the return, the angle of tilt required for the return roller in a horizontal curve will be different to the carry roller. The tilt angle alpha (a) for carry roller is referenced to a horizontal plane (refer Figure 18) and the angle beta ( ) for the return roller is referenced to a plane central to the carry idler, shown as vertical in Figure 18A. For horizontally curved conveyors, generally superelevation profiling of the earth is utilised where a sleeper or slipform pavement foundation design (or other formed - such as concrete - foundation) is utilised.

[0161] Embodiments can include the foundation supported on a superelevated earth pad providing lateral / transverse (relative to a longitudinal conveying direction) inclination to the frame 11 . Consequently, the support structure can ‘bank’ the conveyor belt to accommodate curves. For foundations where superelevation is not feasible, such as bored piers, slabs or pedestals, the addition of appropriately angled bevelled washer (top and bottom) allows for the angle tilt of the frame, relative to a vertical anchor bolt, to be accommodated. Figure 18A shows typical angle ranges for embodiments of the design used iniron ore for horizontal curves between 1800mand 6000m. Return roller slots and survey work points can be rotated relative to the carry roller to accommodate a designers desired offset on belt position relative to a straight conveyor. Rollers can then be fitted as well as stringers and cladding. The tilt angle [3 can be fixed in fabrication with welded manufacture. If observed belt tracking behaviour does not match conveyor design modelled outputs, an adjustable connection design may be required. Adjustability of the tilt angle ([3) may be incorporated in situ relative to the carry positions (a).

[0162] Embodiments can include an adjustment fixing point / position 96 between the upright supports / legs 12, 16 of the frame 11 and the secondary transom 30 (return idler / roller support transom) in the form of a radial slot 96.1 on one connection side (frame) and circular holes 96.2 on the other connection (secondary transom) (e.g., see Figure 18C) for adjustment within the desired arc transcribed by the fixing point from the centre of the top of the central roller at mid plane of the frame. Alternatively, the adjustment fixing point / position 96 may provide a number of horizontal slots 96.3 on one connection side (frame) and vertical slots or holes 96.4 on the other connection (secondary transom) (e.g., see Figure 18D), or vice versa, for discrete angular adjustability.

[0163] Embodiments of the roller support structure, particularly the frame, integrates the roller mounting brackets within the footprint of the upright supports (e.g. legs), avoiding need for a stringer to support the rollers / idlers.

[0164] The frame can be symmetric for carry roller 36, 38 positions about the wing roller 38 central axis, with one or more return rollers asymmetrically mounted on one side of the primary transom 20. This adjustment with the orientation of the frame of the roller support structure installation creating differences in the span between return belt rollers allows for a reduction in potential harmonic belt flap vibrations.

[0165] Major power losses include indentation rolling resistance, bearing seal drag, skew I idler alignment and bulk solid (material) and belt flexure resistance.

[0166] Power loss: Indentation Rolling Resistance (IRR) - It is understood that increasing the roller diameter reduces indentation rolling resistance. As the rubber conveyor belt travels over a conveyor roller, the underside is indented by the weight of the belt and bulk material on the belt. The indentation cycle involves compression of the bottom cover as the belt drives into the roller, followed by recovery as the belt leaves the roller. Since the belt cannot recover at the same rate as it is compressed due to the viscoelastic (time dependent) properties of the rubber, an asymmetric pressure distribution forms, resulting in indentation rolling resistance. The recovery time of a rubber cover is dependent on the viscoelastic properties of the rubber, and is therefore temperature, belt speed and strain dependent.

[0167] In addition, experimental research by Hager and Hintz (1993) and analytical research by Wheeler and Munzenberger (2009) has shown that belts with larger diameter internal steel cords, having identical rubber compounds and cover thicknesses, are known to have greater indentation rolling resistance. Peak pressures occur directly underneath the cords and reduce to mid cord pitch. Larger diameter rollers reduce contact pressure and therefore belt stress at the belt and idler roll interface (Figures 6D1 , 6D2) and subsequently reduce IRR.

[0168] A conveyor belt bends at the junctions between idler rollers. Bending induces compression in the belt’s upper face and tension in the underside face. The idler arrangement, belt properties and belt loading impact the extent of this deformation. The idler junction bending area is along the belt travel direction, symmetric along the belt centre line, and separates the belt’s contact between the adjacent rollers such as centre roller(s) and wing roller(s) as shown in Figure 7 for a three idler roller arrangement. Various belt cover failure mechanisms can present resulting in early cover failure if this is not addressed during design.

[0169] Embodiments of the present invention include a 4-roller arrangement having dual centre rollers and two spaced wing rollers. Beneficially, due to the relatively large diameter of the centre rollers of embodiments, an increased offset spacing exists between the adjacent centre rollers, which spacing is more akin to a conventional span between 3 roller offset idlers. To reduce the load borne by an individual centre roll, embodiments having the 4-roller with dual centre roller arrangement can be utilised. This beneficially reduces the load borne by each centre roller to 35-40% of load. Undertaking this also evens out the disparity between design conditions present between wing rollers and centre rollers, i.e. wing rollers would experience between 15-10% of the centre roller load, making it more viable to have a consistent wing and centre roller arrangement. When centre rollers are smaller and closer together, there is the potential for a pressure imbalance due to the proximity of the adjacent roller and fabrication tolerances. For example, published patent document US 2002 / 0050444 discloses a 4-roller dual centre roll concept that has the centre rollers mounted on a rocker arm to allow for differences in relative belt and load pressure between the centre rollers. The rocker arm arrangement itself may induce resonance, such as with the rocker arm mounted rollers oscillating up and down as the load is carried by the belt across these rollers.

[0170] Embodiments of the present invention can utilise large diameter rollers (relative to standard diameter rollers), such as above 219mm 0, preferably above 250mm 0, more preferably 406mm to 508mm 0, or more, providing greater separation length and high accuracy axle / shaft mounting slots that reduce the potential for this relative pressure distribution.

[0171] A further differentiation of embodiments of the present invention over US 2002 / 0050444 is that localised adjustment of roller height through machining or laser cutting of the roller axle / shaft slot positions can be provided that allow for any uneven pressure distribution present between the centre rollers.

[0172] Power loss: roller seal drag - roller seal drag contributes losses to a conveyor system. For example, if a labyrinth seal geometry is maintained andonly roller outer diameter is increased, then plotting this relationship results in relative losses for a typical labyrinth design, as depicted in the chart of labyrinth seal viscous drag (relative to a 178mm 0 roller) vs idler roller diameter (mm) in Figure 5B. That is a 508mm diameter indentation rolling resistance (IRR) loss would be 35% compared to a 178mm diameter roll.

[0173] Skew / idler roller alignment loss: - Idler roller mounting brackets will typically be designed for a nominal design load rating (tonnes per hour). Due to varying loading that the conveyor system will encounter, the forces with offset idler rollers (3 or 5 rollers) will apply torsion to the frame and displace the idler roller frame, and consequently displace the positions of the roller mounting brackets, skewing the wing rollers perpendicularly to the belt longitudinal line and thus having the potential to increase idler roller skew losses. Inline rollers mitigate this to a great extent due to their symmetrical loading of the idler frame.

[0174] Embodiments of the present invention reduce torsion of the frame and / or primary transom and therefore minimal deflection, due to having symmetry about the wing roller axis. Increasing the idler span between wing roller sets reduces the idler roller skew forces linearly due to having fewer potentially skewed idler rollers. Increasing the accuracy of manufacture of the frame advantageously reduces skew / idler roller alignment loss as they are able to be installed more accurately.

[0175] It has been realised that large diameter idler rollers (e.g. >219mm) advantageously minimise contact stresses and rubber hysteresis losses at the pulley cover and roller interface through a longer contact length and engagement time than smaller diameters (152, 178mm, 203mm and 219mm). See, for example, Figures 5A1 - 5A4. Having dual centre rollers reduces the load borne per roller. Beneficially, larger roller diameter and dual centre roll in combination reduce indentation rolling resistance. For the same bearing size and seal arrangement, larger idler rollers offer lower rotating resistance as a result of their larger radius. A larger radius lowers the angular velocity which results in lower viscous resistance from the grease in the bearings and labyrinth seals and furtherreduces drag. The idler roller junction (junction region (JR), see Figure 7) is defined as the region along the conveyor belt where the inner end of a wing roller (WR) and an outer end of a centre roller (CR) geometry interfaces (e.g. overlaps or are adjacent).

[0176] For an inline idler roller arrangement, where all rollers are at the same plane, there is a gap between adjacent idler rollers. If the gap is wide enough and the belt’s idler roller junction bending is severe enough, the belt can contact the idler roller edge. When this scenario occurs, the idler roller edge acts like a knife edge, where the contact stress between belt and idler roller edge is very high and leads to high rate of cover wear. It will be appreciated that an offset idler roller configuration according to one or mor embodiments of the present invention is more beneficial and helps to reduce belt damage, where the rollers are staggered to create an overlap at the idler roller junction. This eliminates or at least reduces potential contact between belt and idler roller edge. A large diameter idler centre roller and the incorporation of a second centre roller Reduces the contact stress between belt and idler roller, and the idler roller junction bending is reduced through the idler frame, thereby helping to optimise belt wear reduction.

[0177] Pull wire switches 54 and belt drift 52 switches and associated control panels and equipment can be provided as protection systems of an overland conveyor system. An upper limit of 4.5m, preferably 4m, is required between pull wire supports to comply with activation loads. Embodiments of the present invention can include one or more such systems, such as mounted to stringer centrally between consecutive upright supports (such as legs) on one side of the conveyor system and with the increased idler span arrangement this provides greater accessibility to the rollers. Pull wires and pull wire pigtail supporting bracket elevations can be positioned such that the respective roller can be removed through the gap between the pull wire and the stringer without movement of the pull wire. See, for example, Figures 8A to 8D. At least one pull wire switch module can be mounted centrally on the stringer. Embodiments can include a control cabinet - far side and siren / light - near side. See, for example,Fig 8A. Pull wire pigtail support and anchor brackets can be mounted mid span between frames - see, for example, Figure 8C.

[0178] Embodiments can include at least one belt drift switch module, which module may be mounted centrally on stringer, such as shown by way of example in Figure 8D, which shows a representation of a belt drift switch behind guarding.

[0179] Typical pull wire supports (pig tail) leg mounting location with vertical clearance for roller removal between it and the stringer and pull wire bracket located centrally between legs to meet the requirements of AS1755 (i.e. 70N at maximum of 300mm motion at mid support location or 230N along the line to activate the switch.) - see for example Figures 8A, 8B and 8C. Conveyor crossovers are necessary to provide personnel access on both sides of the conveyor without having to traverse the length of the conveyor. An embodiment of the present invention, Figure 17 shows a crossover arrangement 97 designed to minimises maintenance access restrictions for roller changeout.

[0180] A typical 508mm diameter roller with the shell made from schedule 10 steel pipe and a plastic end cap will weigh approximately 60kg. With limits on liftable weights for individual personnel set by many companies at 20kg or 25kg, this health and safety consideration is one of the main reasons preventing the adoption of larger rolls. Larger dual centre rollers offset relative to spaced wing rollers, all mounted in a frame, according to embodiments of the present invention, enables the carry roller mounting brackets 14, 18, 26, 28 to be readily accessible for replacement of rollers 36, 38.

[0181] Embodiments of the present invention, through wide spans, e.g. 6 to 6.75m, enable replacement of rollers through either a robotic / articulated arm or zero gravity assisted lift arm 93 with a gripper arrangement 94 mounted on a service vehicle 95 - see for example Figure 16. The gripper arrangement 94 can have a receptacle of matching profile and dimensions for a shaft end detail arrangement 94.1 . The idler mounting bracket slot 36.1 , 38.1 is located on theshaft 35 of the roller 36, 38 that is of a known angular offset from the idler shaft frame bracket slot, nominally 90 degrees, as shown by example in Figure 28. The roller shaft 35 end detail can be used to positively capture the roller 36, 38, preventing uncontrolled movement during positioning with the arm 93 and for orienting and positioning the roller shaft slots during installation into the idler frame bracket slots.

[0182] Figure 29 shows the clearance geometry that is afforded to the gripper arrangement 94 for accessibility to the shaft end detail arrangement 94.1 with the use of larger diameter rolls.

[0183] The upright support (such as a leg) 12, 16 can be provided to utilise a carry belt lift I handling arrangement 60, such as a hydraulic or electric jack / actuator assembly 63 temporarily mounted on the primary transom to elevate the carry belt 44A , shown in Figure 2) via a lift mechanism 62 (e.g. metal frame 65 profiled in shape of carry belt), as shown by way of example in Figures 9A1 to 9 A3.

[0184] The return belt portion 44B can be lifted in a comparable arrangement, as shown by way of example in Figures 10A to 10C2. A return belt lift / handling arrangement 60.1 , such as a hydraulic or electric jack / actuator assembly 63.1 , 63.2 temporarily mounted on the primary transom to elevate the return belt 44B, shown in Figure 2 via a lift mechanism (e.g. metal frame 65.1 profiled in shape of carry belt), as shown by way of example in Figures 10A to 10C2.Footing / mounting 42 embodiments showing anchor bolts 72 e.g. sleeper 42 sits on prepared surface see Fig 11 A). Forklift tyne / tine slots / channels 43 can be provided through or inset into the sleeper 42, such as slots in an underside of the sleeper or channels through the body of the sleeper.

[0185] Embodiments can include a slab 45 (partially buried in Fig 11 B) and pedestals 47, or bored (partially buried) piers / piles 49, or slipform (formed onprepared surface) foundation / slab 51 , or a truss 80 structure mounted frame 11 , such as depicted by way of example in Figures 11 E1 and 11 E2.

[0186] Figures 11 E1 to 11 E5 show an example of an 18m truss structure in section view (Fig 11 E1 and 11 E3) and isometric view (Fig 11 E2 and 11 E4) with frames 11 mounted at 6m span and 3m offset from end of truss 80. The truss 80 structure can have walkways 82 at one or both sides.

[0187] An 18m truss can have frames 11 mounted at 6m span and 3m offset from end of truss 80 (Fig 12A), 24m truss with frames mounted at 6m span and 3m offset from end of truss (Fig 12B), 30m truss with frames mounted at 6m span and 3m offset from end of truss (Fig 12C), or 36m truss with frames mounted at 6m span and 3m offset from end of truss (Fig 12D).

[0188] Embodiments may include one or more adjustment arrangements for adjusting upright support position relative to a foundation. At least one bolted joint design allows for freedom of moment in multiple, preferably up to six, degrees of freedom. See, for example, embodiments of Figures 4A, 4B and 4C, as well as Figure 19. Embodiments of a bolted joint can include nuts, such as position setting nuts 70.1 and locknuts 70.2, plate washers 74 (e.g. flat or bevelled), frame baseplate 68 with void 68.1 to receive: the respective washer 74, spherical / dished washers 64U1 , 64U2 of an upper spherical / dished washer set 64U, and a nut 70.1 on anchor bolt 72 below the baseplate 68. A lower dished / spherical washer set 64L1 , 64L2 is on the anchor bolt 72 between a plate washer 74 (e.g. flat or bevelled) and a locknut 70.2. It will be appreciated that embodiments need not require, preferably do not have, shimming. Elevation adjustment can be through the height positioning of the bolted joint along the upright anchor bolt 72. Coarse roll positioning can be provided by bevelled washers 74 where the anchor bolt 72 is configured to be vertical or through the sleeper being supported off terrain with superelevation. See, for example, the embodiment shown in Figure 4C.

[0189] A hole 68.1 , preferably oversize diameter, through the baseplate 68 allows for transverse, longitudinal and yaw adjustment. Clearance dimension 68.2 can be equivalent to the anchor bolt 72 diameter, plus civil construction tolerance, plus GPS accuracy, but limited to 20 mm. Civil construction tolerances can be: + / -3 mm for < M24 anchor bolt connections, + / -4 mm for >M24 anchor bolt connections. Plate washer dimensions can be sized to ensure coverage of the void at all anchor bolt positions. See, for example, the embodiment shown in Figure 20.

[0190] Spherical / dished washers 64 (64.1 U, 64.2U, 64.1 L, 64.2L) enable angular degree of offset between true anchor bolt vertical position and actual position (such as up to 3°, preferably up to 5°, angular degree of offset) and / or flatness between nut bearing face and plate washer facing surfaces. Spherical / dished washers within the bolted connection allows for fine roll and pitch adjustment. Figures 21 A to 21 C show applications of a spherical / dished washer 64 arrangement for the bolted connection.

[0191] It will be appreciated that the spherical / dished washers can have a convex curved face on one side, on both sides (to meet with reciprocal concave curved faces of mating components), or a convex curved face on one side and a flat or hollow / concave face on the other. The spherical / dished washers help centralise the load through the anchor bolt when two bearing surfaces are at an angle relative to one another. Spherical / dished washers can include two pieces in spherical contact that adjust to allow for deviation of the anchor bolt from vertical, or a fixture such as the support frame relative to the vertical anchor bolt and foundation, in the horizontal or vertical directions.

[0192] In Figures 21 A to 21 C, d1 represents the diameter of the aperture 64.1 A through spherical washer convex half 64.1 and d3 represents the overall outer diameter of that same half 64.1 . The concave half 64.2 has an aperture therethrough 64.2A having a diameter d5. The combination shown in Figure 21 C shows the angular freedom of 3 degrees for this embodiment for a nut inner diameter d6. Releasing agent can be applied to one or more surfaces of the void,plate washers, locknut and anchor bolt that interface with grout for easy grout removal at decommissioning or future positional adjustment arising from subsidence or other causes of going out of tolerance.

[0193] Offsite pre-assembly of the foundation 42 (e.g. sleeper) with the support frame / legs (11 , 12, 16) with the connection of the anchor bolted joints. Each support frame can be set to its designed installation position relative to the foundation. For transport support and initial positioning, a spacer 68.3 shown in Figure 20B (with plate washer omitted) can be included to restrain the foundation and anchor bolt position to be within civil tolerances relative to the required idler installation position. Similar assembly occurs in situ with non-sleeper foundations. The position of the anchor bolt will be to civil tolerances. As a result, the idler baseplate void clearances 68.2 for these foundation types, can be reduced from GPS tolerances up to 20mm, to civil tolerances plus allowances for clearance of the anchor bolt due to frame roll requirements relative to anchor bolt verticality. Pre-assembled foundations 42 and frames 11 can be transported to the installation site (see, for example, Figures 14A and 14B showing non-limiting examples of transport options). The pre-assembled foundations and frames can be loaded and unloaded from a trailer / flat rack container by forklift or other type lifter / carrier.

[0194] A survey jig 90, such as a dual satellite navigation / positioning or global positioning system (GPS) survey jig, can be employed for coarse positioning of both the foundation (e.g. sleeper) and support frame (idler frame), such as the preassembled foundation and frame. This can be a manual operation or machine- controlled operation, or a combination thereof. Satellite navigation / positioning or GPS modules can be offset from each other by a separation distance, such as >1 m distance. See, by way of example, Figures 22A to 22D showing a survey jig 90 mounted to a support frame 11 . Preferred embodiments can have the dual GPS units mounted to the jig with zero offset to the jig and frame centreline position that aligns with the conveyor centreline. The satellite navigation / positioning or GPS can include or use a real-time kinematic positioning (RTK) system for location / positioning accuracy to correct for common errors incurrent satellite navigation (GNSS) systems. A network RTK base station can provide installation positional accuracy to within 8mm horizontal and 15mm vertical and with 0.5mm added in all dimensions for every 1 km of distance the satellite navigation / positioning system or GPS is located from the RTK base station. Satellite navigation / positioning or GPS can include a tilt sensor such as Inertial Measurement Unit utilising microelectron-mechanical systems (MEMS) including a three-axis accelerometer and a three-axis gyroscope to precisely measure acceleration and angular velocity.

[0195] The pre-assembled frame 11 and foundation 42 can be supported dynamically via a mechanism attached through fixings within the foundation, support frame, or both, such as those in Figures 13 to both position and restrict or prevent uncontrolled movement.

[0196] Embodiments can include using rectangular prism survey accuracy dimension + / - 4mm horizontal, a maximum longitudinal centreline angular offset between units of 0.42degrees can be achieved at a 1100mm offset. Preferably, further precision survey may be required to achieve required tolerance. See, by way of example, the arrangement shown in Figure 23. Embodiments can include a survey jig 90, such as a dual optical prism survey jig 90.1 , (with or without inertial measurement), deployed on the support frame 11 (e.g. idler frame). The jig 90 / 90.1 can sit directly in the high precision slots 26.1 , 26.2, 28.1 , 28.2 of the centre roller mounting brackets 26, 28 configured to receive the longitudinally spaced dual centre rollers 36 or on top of the rollers 36. Using the slots to mount the jig 90 / 90.1 is preferable to reduce tolerance stack error accumulation; however, with a 0.2mm total indicated runout (T.I.R. or TIR) expected on composite rollers, this will still meet the tolerance specifications.

[0197] Preferred embodiments can have the dual optical prism, with or without inertial measurement, mounted to the jig with zero offset to the jig and frame centreline position that aligns with the conveyor centreline.

[0198] A totalising station, such as of 1”, 2” or 5” angular accuracy, can be employed. Commercially available totalising stations have a standard deviation angular accuracy of equivalent mgon i.e. 1” / 0.3mgon 2” / 0.6 mgon and 5” I 1 .5mgon in vertical and horizontal positions. 1 mgon = 0.00027°, 1” = 0.000278°. For distance measurements, totalising station units can be accurate to 1 mm +1 ,5mm per km within 1 standard deviation of uncertainty. A 2” totalising station is a commercial trade-off between the cost of precision survey equipment and the time lost from repositioning and calibrating less accurate machines.

[0199] Using rectangular survey accuracy dimensions of 1 mm in horizontal and vertical positions. To achieve 0.1 degrees angular offsets (Yaw and Pitch) the optical prisms are preferably greater than 573mm apart. A maximum longitudinal centreline angular offset between units of 0.05 degrees can be achieved where optical prisms are mounted at 1100mm apart. Therefore, a 2” totalising station can be set back from the worksite to a maximum of 106m, a 1” totalising station can be set back from the worksite 212m and a 5” totalising station can be set back from the worksite 42m before requiring to be advanced to the next position. The zero-offset located optical prisms 92 on jig 90.1 can include an integral or independent tilt sensor(s) such as Inertial Navigation System featuring Inertial Measurement Unit (IMU) utilising microelectronmechanical systems (MEMS) including a three-axis accelerometer and a three- axis gyroscope to precisely measure acceleration and angular velocity and therefore 0.1 degrees angular offsets (Roll). See, by way of example, the arrangement shown in Figure 24A - 24D.

[0200] To achieve 0.1 degrees angular offsets (roll) without a tilt sensor such as an IMU, an alternative embodiment of the optical prism jig can be utilised, shown in Figure 15, whereby the at least two prisms are mounted on the jig arm aligned with the wing roller slots. Achieving a rectangular cube survey accuracy dimension 1 mm in horizontal, vertical and distance positions at >573mm offset between centre points of optical prisms therefore achieves tolerances on translation and rotation through the tolerance stack as shown in Figures 26A and 26B.

[0201] To prevent uncontrolled movement of and to support the frame, whilst the anchor bolted joints are loose and the frame position is being adjusted, attachment methods such as those in Figures 13 can be utilised. At the point where the tolerances are achieved, the anchor bolted joint can be tightened to bolting specification (e.g. AS4100 Gr8.8 snug fit as a minimum, or equivalent international standard). The void can be filled with grout e.g. in a similar manner to a casting process with at least two holes 74.1 in the upper plate washer, one pouring cup / filling hole and at least one vent / riser. Any further bolt tightening required is completed after grout has set.

[0202] Embodiments can include a stringer 98 having at least one horizontal slot 99 for bolted interface connection to the support frame / idler frame. Slot length Ls can be dimensioned to ensure the longitudinal adjustment required for the satellite positioning system or combined GPS and prism positioning accuracy.

[0203] One or more embodiments, such as shown by way of example in Figures 31 A to 31 F, can be arranged and configured to support multiple carry rollers of relatively large carry roller diameter, such as 508mm (20”). The example shown provides for eight such offset carry rollers 136, 137, 138, at a 22.5 and 55° inclination, and two 178mm (7”) vee configuration return rollers 150 with standoff mounting to transverse frame neutral axis. It will be appreciated that other numbers of carry and return rollers can be utilised. Further examples are provided in the accompanying drawings and description.

[0204] For example, Figures 32A to 32F show features of at least one embodiment of the present invention for eight 508mm (20”) offset carry rollers 136 (inboard parallel rollers), 137 (intermediate roller / carry rollers), 138 (outboard carry rollers) at 22.5 and 55° inclination, and two relatively larger diameter (406mm (16”)) inline vee return rollers 150.1 with the return transom mounting inline to transverse frame neutral axis. Mounting returns inline to transverse frame changes where moment loads are applied.

[0205] By way of further example, Figures 33A to 33H show features of at least one embodiment of the present invention for four 508mm (20”) offset carry rollers 136, 138 at 45° inclination and three 406mm (16”) offset return rollers 150.1 at 25° inclination with the return transom mounting inline to frame transverse neutral axis. The return transom can be independent or integral to structure in embodiments. In another example, Figures 34A to 34G show features of at least one embodiment of the present invention with six 508mm (20”) offset carry rollers 136, 137, 138 at 22.5 and 45° inclination, and three 406mm (16”) offset return rollers 150 at 25° inclination (mounting inline to frame transverse neutral axis). Such an embodiment enables reduction in belt and bulk flexure losses on the carry profile. It will be appreciated that a survey jig can be mounted across two central rollers slots on each side.

[0206] Shorter face widths on such relatively large (e.g. 508mm diameter) rollers (136, 137,138) provide for 20kg roller weight limits with thicker pipe materials or maintain flexural rigidity within reasonable limits for less stiff materials.

[0207] Embodiments with a return transom standoff mounting can help to reduce conveyor belt flap on the return strand by ensuring different node lengths between adjacent return idlers when alternating installation orientations to left and right handing.

[0208] It will be appreciated that embodiments of the present invention can provide a structural support frame, preferably fully welded, incorporating carry and return roller support brackets having roller shaft 35 mount slots that are prealigned for each respective roller.

[0209] The support frame can be prefabricated offsite, brought to site, installed as a unitary support frame and the required carry and return rollers installed that will be accurately aligned due to the pre-aligned mounts / slots. Installation of the support frame can be aligned with other such support frames through an alignment jig and / or adjustment at feet of uprights / legs of the support frame.

[0210] One or more embodiments of the present invention may include the roller support structure configured to support: i) at least a pair of centre rollers arranged one leading / forward and one trailing / rearward with respect to conveyor belt direction of travel, ii) at least one pair of intermediate rollers, and iii) wing rollers spaced transversely relative to a longitudinal extent of the conveyor belt, the centre rollers and the intermediate rollers being between the spaced wing rollers, wherein the centre rollers are spaced longitudinally from one another relative to the direction of travel of the conveyor belt such that the intermediate rollers are within a maximum forward projection of the forward centre roller and a maximum rearward projection of the rearmost centre roller.

[0211] Embodiments may include pairs of said intermediate rollers, each of said pairs of intermediate rollers provided either side of the centre rollers with respect to a transverse direction of the conveyor belt. Embodiments may include the primary transom supporting intermediate roller brackets to support at least dual intermediate rollers either side of the centre rollers. The intermediate roller brackets have roller axle supports within a forward and rearward extent, relative to conveyor belt longitudinal extent, of the respective centre roller support bracket axle supports for the centre rollers.

[0212] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

CLAIMS:1 . A conveyor installation arrangement including a roller support structure for supporting a conveyor belt of a troughing or endless conveyor, the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, wherein the support structure includes roller shaft slots with machined slot tolerances to receive the respective roller shafts.

2. The conveyor installation arrangement of claim 1 , including threaded fastener connection between the frame and a foundation having six degrees of freedom of adjustment in translation and rotation.

3. The conveyor installation arrangement of claim 2, wherein the threaded fastener connection includes an adjustment arrangement with at least one spherical or dished washer arrangement.

4. The conveyor installation arrangement of claim 3, wherein the spherical or dished washer arrangement provides fine roll and pitch adjustment for the frame.

5. The conveyor installation arrangement of any one of claims 2 to 4, wherein elevation adjustment is by the positioning on at least one anchor bolt of the respective threaded fastener.

6. The conveyor installation arrangement of claim 5, including bevelled washers providing coarse roll positioning, where the anchor bolt is designed vertical or through the sleeper being supported off terrain with superelevation.

7. The conveyor installation arrangement of any one of the preceding claims, including an oversize hole or void through a baseplate for transverse, longitudinal and yaw adjustment.

8. The conveyor installation arrangement of claim 7, including at least one plate washer dimensioned to cover the hole or void at all anchor bolt positions.

9. The conveyor installation arrangement of any one of the preceding claims, wherein a foundation, the frame or both include(s) at least one of: multiple channels, concrete block outs, forklift tyne / tine slots and / or channels, openings / cut outs to twist lock dimensions or other arrangements that allow controlled and supported means of relocation and adjustment, or a combination of any two or more thereof.

10. The conveyor installation arrangement of any one of the preceding claims, including at least one survey jig for coarse positioning of a preassembled foundation and the frame.11 . The conveyor installation arrangement of claim 10, the at least one survey jig including a dual satellite positioning system or GPS survey jig, with or without inertial measurement.

12. The conveyor installation arrangement of claim 10 or claim 11 , including a dual optical prism survey jig positioned on the frame, with or without inertial measurement.

13. The conveyor installation arrangement of any one of claims 10 to 12, wherein the at least one survey jig mounts directly in the roller slots or on top of the rollers.

14. The conveyor installation arrangement of any one of claims 10 to 13, including rectangular survey accuracy dimensions of 1 mm in horizontal and vertical positions.

15. The conveyor installation arrangement of any one of claims 10 to 14, including 0.1 degrees yaw, pitch and roll angular offsets with the optical prisms greater than 573mm apart.

16. The conveyor installation arrangement of any one of the preceding claims, including at least one stringer having a horizontal slot for bolted interface connection to the idler.

17. The conveyor installation arrangement of claim 16, wherein the slot length enables longitudinal adjustment required for the GPS and prism positioning accuracy.

18. The conveyor installation arrangement of claim 17, wherein at least one of the rollers has a shaft end arrangement that allows a receptacle on a gripper at the end of an arm to positively capture the shaft for orientation and positioning within the receiving frame.

19. The conveyor installation arrangement of any one of the preceding claims, at least a pair of the centre rollers arranged one leading / forward and one trailing / rearward with respect to a direction of travel of the conveyor belt, at least one pair of intermediate rollers, and the wing rollers, the centre rollers and the intermediate rollers being between the spaced wing rollers, wherein the centre rollers are spaced longitudinally from one another relative to the direction of travel of the conveyor belt such that the intermediate rollers are within a maximum forward projection of the forward centre roller and a maximum rearward projection of the rearmost centre roller.

20. The conveyor installation arrangement of claim 19, including pairs of said intermediate rollers, each of said pairs of intermediate rollers provided either side of the centre rollers with respect to a transverse direction of the conveyor belt.21 . A method of installation of a roller support structure for a conveyor system, the roller support structure for supporting a conveyor belt of a troughing or endless conveyor, the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, wherein the support structure is preassembled with roller shaft slots having machined slot tolerances to receive the respective rollers / roller shafts.

22. The method of claim 21 , including providing threaded fastener connection between the frame and a foundation having six degrees of freedom of adjustment.

23. The method of claim 21 or claim 22, including enabling adjustment in the threaded fastener connection with at least one spherical or dished washer arrangement.

24. The method of claim 21 , 22 or 23, including using the spherical or dished washer arrangement to provide fine roll and pitch adjustment for the frame.

25. The method of any one of claims 21 to 24, including providing elevation adjustment by positioning on at least one anchor bolt of the respective threaded fastener.

26. The method of any one of claims 21 to 25, including providing coarse roll positioning through bevelled washers, where the anchor bolt is designed vertical or through the sleeper being supported off terrain with superelevation.

27. The method of any one of claims 21 to 26, including providing transverse, longitudinal and yaw adjustment by an oversize hole or void through a baseplate.

28. The method of claim 27, including providing at least one plate washer dimensioned to cover the hole or void at all anchor bolt positions.

29. The method of any one of claims 21 to 28, including providing a foundation and / or the frame, wherein the foundation, the frame or both include(s) at least one of: multiple channels, concrete block outs, forklift tyne / tine slots and / or channels, openings / cut outs to twist lock dimensions or other arrangements that allow controlled and supported means of relocation and adjustment, or a combination of any two or more thereof.

30. The method of any one of claims 21 to 29, including the use of at least one method of temporary physical attachment to the frame, foundation, or both for controlled and supported means of relocation.31 . The method of any one of claims 21 to 30, including mounting at least one survey jig for coarse positioning of a preassembled foundation and the frame.

32. The method of claim 31 , including at least one said survey jig including a dual satellite positioning system or GPS survey jig.

33. The method of claim 32, including providing a dual optical prism survey jig positioned on the frame, with or without inertial measurement.

34. The method of claim 31 , 32 or 33, including mounting the respective survey jig in the roller slots or on top of the rollers.

35. The method of any one of claims 31 to 34, including providing rectangular survey accuracy dimensions of 1 mm in horizontal and vertical positions.

36. The method of any one of claims 31 to 35, including providing 0.1 degrees yaw, pitch and roll angular offsets with the optical prisms greater than 573mm apart.

37. The method of any one of claims 21 to 36, including providing at least one stringer having a horizontal slot for bolted interface connection to the idler.

38. The method of claim 37, the respective slot having a slot length providing longitudinal adjustment required for the GPS and prism positioning accuracy.

39. The method of any one of claims 21 to 38, wherein the idler roller shaft is oriented and positioned via a shaft end arrangement and pair of mating receptacles mounted on a gripper at the end of a manipulation I installation arm.

40. A roller support structure for supporting a conveyor belt of a troughing or endless conveyor on rollers, the roller support structure arranged and configured to support at least one centre roller and at least two spaced wing rollers, the roller support structure including a frame having transversely spaced upright posts connected by a primary transom extending therebetween, the primary transom supporting centre roller brackets to support dual centre rollers, and first and second wing roller mounting brackets for supporting respective first and second spaced wing rollers either side laterally of the centre roller brackets, wherein the centre roller brackets are configured to support dual centre rollers offset relative to a shaft axis of the first and second wing rollers.41 . The roller support structure of claim 40, wherein the upright supports include transversely spaced legs.

42. The roller support structure of claim 40 or claim 41 , wherein an outer end of a respective roller shaft of the first and second wing rollers is supported on an inclined bracket attached directly to the respective one of the spaced upright posts such that the respective roller shaft is symmetrical about a principal axis of the respective upright post.

43. The roller support structure of claim 42, including a secondary transom asymmetrical to and offset about the principal axis of the respective upright post.

44. The roller support structure of claim 43, wherein the secondary transom includes return roller brackets for supporting a return belt portion of the conveyor belt.

45. The roller support structure of claim 44, wherein the return roller brackets support respective return rollers in a V, flat or inverted V configuration.

46. The roller support structure of any one of claims 40 to 45, wherein at least one of the upright supports is secured at a base thereof to a foundation.

47. The roller support structure of claim 46, wherein the foundation includes one or more of a sleeper, bored pier, slab, slab and pedestal, slip form paving or truss.

48. The roller support structure of claim 46 or claim 47, including a mounting arrangement providing up to six degrees of freedom of mounting adjustment between the foundation supporting the frame and the upright supports of the frame.

49. The roller support structure of claim 48, wherein the mounting arrangement includes inclination adjustment.

50. The roller support structure of claim 49, wherein the inclination adjustment is provided at the feet or base of the respective upright support(s).51 . The roller support structure of any one of claims 46 to 50, wherein the foundation is supported on a superelevated earth pad providing lateral / transverse inclination to the frame.

52. The roller support structure of any one of claims 40 to 50, wherein a respective outer extent of the wing roller mounting brackets is contained within an area in plan view of the foundation, enabling offsite preassembly and optimisedtransportation nesting efficiencies within standard transportation dimensions of shipping containers.

53. The roller support structure of any one of claims 40 to 52, wherein location of the frame relative to the foundation is adjustable by adaption of either or both of the upright supports or the foundation.

54. The roller support structure of any one of claims 46 to 53, wherein the foundation includes at least one of: multiple channels, concrete block outs, forklift tyne / tine slots and / or channels, openings / cut outs to twist lock dimensions or other arrangements that allow powered means of relocation, or a combination of any two or more thereof.

55. The roller support structure of any one of claims 40 to 54, wherein tilt inclination adjustment includes the upright supports / legs and the carry rollers or return rollers, or both, tilted to provide stabilising force on horizontal curves.

56. The roller support structure of claim 55, wherein the tilt inclination adjustment includes at least one adjustment attachment point between the upright supports / legs of the frame and the secondary transom / return idler / roller support transom.

57. The roller support structure of claim 56, wherein the tilt inclination adjustment includes a radial slot on one connection side / frame and holes on the other connection / secondary transom for adjustment within the desired arc transcribed by the fixing point from the centre of the top of the central roller at mid plane of the frame.

58. The roller support structure of claim 57, wherein the tilt inclination adjustment includes a number of horizontal slots on one connection side / frame and upright / vertical slots or holes on the other connection / secondary transom, or vice versa, for discrete angular adjustability.

59. The roller support structure of any one of claims 40 to 58, the primary transom supporting intermediate roller brackets to support at least dual intermediate rollers either side of the centre rollers.

60. The support structure of claim 59, wherein the intermediate roller brackets have roller axle supports within a forward and rearward extent, relative to conveyor belt longitudinal extent, of the respective centre roller support bracket axle supports for the centre rollers.61 . A conveyor roller support system for a conveyor system, including at least two roller support structures of any one of the preceding claims, the roller support structures arranged with at least one stringer connecting between upright members.

62. The conveyor roller support system of claim 61 , including at least one of: roof cladding, belt drift switch, siren, light, control panel, pull wire / lanyard switches or pull wire / lanyard support brackets fixed to the respective stringer, or a combination of any two or more thereof.

63. The conveyor roller support system of claim 61 or claim 62, provided as a module whereby dimension between a conveyor pull wire / lanyard location and a bottom of the stringer is such that carry idler rollers are removable unencumbered by interference with the conveyor pull wire / lanyard and the stringer.

64. The conveyor roller support system of any one of claims 61 to 63, wherein the respective carry idler rollers are automatically, manually, or partially manually removable via an assisted lift / zero gravity balance arm or robotic arm, including those proximal to a conveyor personnel cross over.

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