SYNCHRONIZATION OF CONVEYOR BELT AND DRIVE OF AN INCLINED CONVEYOR

Description

[0001] The invention relates to a device for the controlled drive of a steep conveyor and a method for controlling a steep conveyor, wherein a reduction in wear, an extension of the service life of the components and / or the lowest possible friction operation is made possible by synchronizing the conveyor and drive belt.

[0002] A steep-angle conveyor's function is to transport goods or bulk materials diagonally or vertically upwards. The conveyor belt typically features appropriate drive profiles on the drive side. The conveying side of the belt is equipped with features such as corrugated edges with cross cleats or buckets mounted on the conveying side.

[0003] The conveyor belt is typically driven by drive profiles through the engagement of, for example, rods mounted on the continuously driven belt. Depending on the length of the conveyor belt, several drive systems can be installed along the conveyor line to move the belt over specific sections and to apply the required drive forces in a metered manner.

[0004] Since the conveyor belt stretches differently depending on pretension and load, in addition to its own weight, along the varying inclines (flat, inclined, vertical, downhill) of the conveying path, this can lead to increased wear and a reduced service life of the coupling system between the conveyor belt and the drive belt. This is because the pitch or spacing of the conveyor belt's tooth profiles can change. As a result, the conveyor belt's tooth profiles no longer fit optimally into the coupling profiles of the conveyor drive system, leading to increased component wear and potentially even drive system failure.

[0005] In WO 2018 / 153651 A1 ,The invention, which discloses the features of the preamble of claims 1 and 13, shows a belt conveyor with a carrying belt and a drive belt. A drive system is provided for driving the drive and carrying belts. The drive system has a drive for the carrying belt and a drive for the circulating drive belt. A tensioning device is provided for tensioning the carrying belt and the drive belt. The tensioning force introduced by the tensioning device acts on the carrying belt and the drive belt(s) by means of a deflection drum associated with the carrying belt and a deflection drum associated with the drive belt(s) that is mechanically coupled to this deflection drum. Therefore, only one tensioning device is required for tensioning the carrying belt and the drive belt(s).

[0006] DE 32 35 471 A1 shows a scraper conveyor with a conveying trough and a longitudinally movable guide therein, wherein drivers are provided which engage forcefully behind the scrapers and introduce the drive force directly into the scrapers.

[0007] WO 2005 / 035404 A1 is another conveying device with a pipe conveying circuit and endless conveying media circulating through the pipe conveying circuit.

[0008] It is an object of the invention to create a device for the controlled driving of a steep conveyor and a method for controlling a steep conveyor that enable reduced wear and an increase in the service life of the drive components.

[0009] According to the invention, a device for the controlled driving of a steep conveyor is provided, which has a control unit that enables synchronization of the conveyor and drive belt of the steep conveyor in such a way that an exact engagement takes place between the coupling profiles of the conveyor drive system and the tooth profiles of the conveyor belt.

[0010] This can significantly increase the lifespan of the overall system, as there is reduced wear and tear on the components.

[0011] Due to varying loads on the conveyor belt, its own weight, introduced pre-tensions, and differing moduli of elasticity in individual belt sections, different elongations of the conveyor belt occur along the conveying path. These varying elongations, in turn, lead to different spacings of the tooth profiles along the conveying path.

[0012] According to the invention, a sensor unit is provided for determining the weight of the conveyed material, including the weight of the conveyor belt, wherein the weight (or partial weights) is assigned to specific sections of the conveyor belt. The control unit can assign a specific weight to each section of the conveyor belt (digital twin).

[0013] Furthermore, the control unit can determine the length L of the respective subsections T in a steep conveying section S of the conveyor belt from the different partial weights. From these partial lengths, the control unit can then determine the desired distances B of the coupling profiles of the drive belt across the steep conveying section S and adjust the elongation of the drive belt so that a synchronized and adapted division of the coupling profiles to the tooth profiles is achieved.

[0014] Instead of setting an axle spacing C of deflection rollers of the conveyor drive system, it is also possible to introduce a corresponding tensile force into the drive belt via one or more additional rollers.

[0015] It should also be expressly noted that the tooth profiles can be provided on the drive belt and the coupling profiles on the conveyor belt (conversely to the design described below).

[0016] The optimized spacing of the drive belt's coupling profiles, which engage with the tooth profiles, ensures optimal engagement and thus optimal power transmission. This results in reduced wear from relative movements, a longer component lifespan, and low-friction operation. Furthermore, it prevents the drive system from skipping and ensures that operational events such as the failure of one or more drive systems do not cause problems.

[0017] Synchronization of the conveyor and drive belt can be achieved by a variable adjustment of the pretension and thus the elongation of the drive belt, so that the mounted coupling profiles of the drive belt are adjusted in their pitch to the respective current pitch of the tooth profiles of the conveyor belt.

[0018] To adjust the elongation / pretension of the drive belt, the current elongation of the conveyor belt can be determined immediately before the coupling profiles engage with the tooth profiles.

[0019] It should be noted that the coupling profiles can also be provided on the conveyor belt and the tooth profiles on the drive belt.

[0020] The determination of the current strain of the conveyor belt immediately before the coupling profiles engage with the tooth profiles can be carried out via a corresponding calculation and / or simulation, by determining the exact loading state and the position of the loading state along the conveyor route for each or at least for relevant positions and from this the resulting strain over the conveyor route (digital twin).

[0021] The conveyor belt can have different inclines in different sections. Part of the conveyor can be flat or horizontal, another part inclined at a specific angle upwards or downwards, and / or yet another part vertically upwards. Due to the resulting varying weight forces acting on the conveyor belt, and additionally due to the varying weight forces of the conveyed material (especially if the material is not evenly and / or homogeneously distributed on the belt), different lengths or elongations / stretchings of the conveyor belt occur, depending on the respective modulus of elasticity (or moduli of elasticity) of the conveyor belt in different sections.

[0022] According to the invention, it is possible to determine the resulting elongation at any position of the conveyor section, in particular at the inlet of the conveyor belt to the drive belt.

[0023] This can be achieved by recording various measured parameters (such as the conveyor belt load) and the characteristic values ​​of the conveyor belt (tension / elongation behavior) and the drive belt. A permanent digital model of the conveyor system, a so-called digital twin, is created. This allows the elongation state or partial length in specific sections of the conveyor belt to be determined and used as a control variable for adjusting the pretension / elongation of the respective conveyor drive system.

[0024] A sensor unit containing a weighing device can be provided. The weighing device can transmit the determined weight to the control unit. The weight transmitted to the control unit is assigned to a predetermined section of the conveyor belt.

[0025] The sensor unit can contain a sensor that transmits information about the fill quantity of conveyed material to the control unit. The control unit can be configured to determine a weight from this information.

[0026] Furthermore, one or more signal transmitters can be provided on the conveyor belt at predetermined intervals along the longitudinal direction of the conveying path 19. These signal transmitters can be detected by a position sensor, which transmits position information to the control unit. Based on this position information, the control unit can be configured to assign the respective weight of the conveyed material to the predetermined sections. Consequently, the control unit can be configured to have precise information at all times about the location of each conveyor belt section.

[0027] The signal transmitter can be an optical signal transmitter, a mechanical signal transmitter, an electromagnetic signal transmitter (e.g., a Hall sensor), and / or an X-ray source. The corresponding position sensor can be configured to receive the position signals.

[0028] The transmitted position signals contain, for example, an identifier (ID) which can clearly tell the control unit where each section of the conveyor belt is currently located.

[0029] Because the control unit is informed about the current position of the conveyor belt along the conveyor track, knows the gradient of each section of the conveyor track, knows the quantity of material being conveyed in each section, and / or can determine the resulting elongations or lengths of the conveyor belt sections, it is possible to achieve optimal synchronization of the conveyor belt with the drive belt. This is because the pitch of the drive belt's coupling profiles can be precisely adjusted to match the incoming tooth profiles of the conveyor belt (as the conveyor belt enters the drive belt).

[0030] Based on the weight information in the predetermined sub-areas, the control unit can determine the lengths and / or elongations of the conveyor belt assigned to the sub-areas, particularly along a steep conveyor section S.

[0031] Furthermore, the control unit can be configured to determine the lengths and / or elongations of the conveyor belt assigned to the sub-areas via the self-weight of the conveyor belt, the recorded or determined weight of the conveyed material, the E-modulus(s) of the conveyor belt (the conveyor belt can consist of different conveyor belt sections with different E-moduli) and / or the gradient(s) of the steep conveying section S.

[0032] By synchronizing the drive belt accordingly, or by synchronizing the elongation / tension of the drive belt, a very precise engagement of the drive components can be achieved, leading to a significantly increased service life of the components and low-friction operation with optimal force transmission.

[0033] The control unit must be configured to translate the determined conveyor belt lengths into the required spacing of the drive belt's coupling profiles. Furthermore, the control unit must be configured to essentially align or synchronize the spacing B of the drive belt's coupling profiles engaging the tooth profiles with the spacing A of the tooth profiles by adjusting the drive belt's elongation, and thus the coupling profile spacing B, via the conveyor drive system's actuator. This can be achieved, for example, by adjusting the center-to-center spacing of the drive belt's deflection pulleys and / or by using one or more additional pulleys to apply a corresponding elongation force to the drive belt.

[0034] It may also be possible to determine the respective elongation or length of the conveyor belt sections, and thus the respective distances A of the conveyor belt's tooth profiles, by means of a measurement, and then use this measurement to adjust the distances B of the drive belt's coupling profiles accordingly. For this purpose, profile lugs can be attached to individual or all teeth in certain tooth profile sections. These can be used to provide information about the longitudinal elongation of the conveyor belt at the respective measurement position.

[0035] The same applies to the elongation or spacing of the drive belt's coupling profiles. The aforementioned profile lugs or markings can, for example, also be attached to the drive belt's coupling profiles. During operation, the distance between these profile lugs can then be measured, allowing for optimized synchronization of the conveyor belt with the drive belt.

[0036] It should be explicitly noted at this point that, for example, a measurement of only the distance between two or more tooth profiles of the conveyor belt and / or the distance between two or more coupling profiles of the drive belt may be sufficient.

[0037] The control unit can also be configured to determine a distance D between an upper edge of the tooth profile and a top surface of the drive belt via a detection unit and to use the distance D as a feedback control variable for the center distance C or the required elongation / length of the drive belt, whereby if a predetermined limit distance D is exceeded, the distance C or the required elongation / length of the drive belt can be adjusted accordingly.

[0038] Furthermore, a method for controlling a steep conveyor is provided, which can determine the weight of a conveyed material via a sensor unit. This weight can be assigned to a predetermined section of the conveyor belt, and the sensor unit can be configured to transmit information about the weight to a control unit. Additionally, a length within a steep section of the conveyor belt, corresponding to the predetermined section, can be determined by the control unit from the weight information. Furthermore, the center distance C of deflection rollers in a conveyor drive system can be set based on the lengths assigned to the predetermined sections.

[0039] The aforementioned means and measures make it particularly advantageous to achieve optimal synchronization of the conveyor and drive belt of an inclined conveyor, thereby significantly reducing wear on the drive components and thus considerably extending their service life. Furthermore, the drive can be operated with minimal friction and precise alignment.

[0040] Furthermore, events such as a failure of a conveyor drive system, and thus a partially greater stretching of the conveyor belt, can also be compensated for by the synchronization of the conveyor and drive belts according to the invention. The invention is described in more detail below by way of example with reference to the accompanying schematic drawings. These show: Fig. 1 a schematic representation of the funding system, Fig. 2 a representation of the control unit with associated units, and Fig. 3 An enlarged view of the space between the conveyor belt and the drive belt.

[0041] The following describes various examples of the present invention with reference to the figures. Identical or similar elements in the figures are designated by the same reference numerals. However, the present invention is not limited to the described embodiments, but further comprises modifications of features of the described examples and combinations of features of different examples within the scope of the independent claims.

[0042] Fig. 1 Figure 1 shows a conveyor system 1 with a conveyor belt 2. Support elements 3 are attached to the conveyor belt 2. The support elements 3 serve to prevent the conveyed material 4 applied to the conveyor belt 2 from slipping off the conveyor belt 2 when it is moved diagonally or vertically upwards along a conveying path 19.

[0043] The conveyor section 19 can be configured differently depending on the conveying task. For example, the conveyor section 19 can initially move horizontally, then slightly diagonally upwards or downwards, then vertically, then again slightly diagonally upwards or downwards and then horizontally again, etc. (not shown).

[0044] Furthermore, conveyor drive systems 5 are shown, with only two conveyor drive systems 5 being shown as examples. Of course, depending on the requirements and conveyor length 19, several such conveyor drive systems 5 may be provided.

[0045] A weighing device 9 can be provided which can weigh the conveyed material 4 and / or the conveyor belt 2 with the conveyed material 4 on it. The determined weight G 1-n can then be transmitted to a control unit 15 (see Fig. 2 Signal transmitters 10 are provided on the conveyor belt 2. These signal transmitters 10 can be designed as optical signal transmitters, mechanical signal transmitters, electromagnetic signal transmitters, and / or X-ray sources. It should be expressly noted that other signal transmitters or active or passive markers may also be provided. One or more position sensors 11 are provided, coordinated with the signal transmitters 10, to detect their passage. The position sensor 11 and / or an associated device is able to locate the passing signal transmitters 10 on the conveyor belt 2 in such a way that specific sections T1-n of the conveyor belt 2 can be defined and identified.

[0046] This makes it possible, for example, for the device for the controlled drive of the steep conveyor to generate a digital representation of the conveyor system and thus create a digital twin. The control unit 15 can then assign the weight of the conveyor belt 2 with conveyed material 4, as recorded by the weighing device 9, to a subsection T 1-n of the conveyor belt 2. Furthermore, the control unit 15 can sum the weights of specific subsections T 1-n. This is shown in the schematic diagram in Fig. 1 For example, the weight of four sections T1-n of the conveyed material 4 (upper conveyor drive system 5) would be added to the weight of the conveyor belt 2, starting from where it exits the engagement of the lower conveyor drive system 5, to determine the corresponding elongation of the conveyor belt 2. This allows the weight of the conveyor belt 2 with the conveyed material 4 mounted on it to be taken into account. Depending on the resulting elongation or length L1-n of the corresponding sections T1-n, an actuator 6 of the conveyor drive system 5 can then be actuated such that the tension or stretch of the drive belt 12 is adjusted so that the distances B of the coupling profiles 13 of the drive belt 12 are synchronized with the distances A of the tooth profiles 14 of the conveyor belt 2.This ensures optimal engagement of the coupling profiles 13 with the tooth profiles 14, resulting in significantly reduced wear due to relative movements, significantly reduced friction and thus a longer service life of the drive components.

[0047] In the Fig. 1 The drive units 7 of the conveyor drive systems 5 are also shown, each driving a deflection pulley 16. This deflection pulley 16, in turn, drives the drive belt 12, for example, by friction. The actuator 6 acts, for example, on a deflection pulley 16, allowing the deflection pulley to be moved longitudinally. By moving the deflection pulley 16 longitudinally, the tension or elongation of the drive belt 12 can be adjusted so that the distance B between the coupling profiles 13 can be set. By adjusting the distance B to match the previously determined distance A between the tooth profiles 14, optimal synchronization of the drive system is possible.

[0048] The control unit 15 is able to determine the acting weight force due to the conveyed material 4 located in the support elements 3 and the conveyor belt length, based on knowledge of the conveying section 19 and the existing inclination of the conveying section 19. This is possible because the corresponding weight G 1-n was previously determined by the weighing device 9 and assigned to a corresponding sub-area T 1-n via the markings and the corresponding position sensors 11.

[0049] Consequently, the control unit 15 can determine the elongation in specific sections T1-n of the conveyor belt 2 and ascertain when and where this elongation occurs along the conveyor path. This local allocation of the length or elongations along the conveyor path of the conveyor belt 2 allows the drive belt 12 to be optimally synchronized and adjusted to the elongation.

[0050] In Fig. 2 The control unit 15 is shown schematically. The control unit 15 is electrically and / or wirelessly connected to the optical sensor 8, the weighing device 9, the signal transmitters 10, the position sensor(s) 11, the actuator 6 and the drive unit 7.

[0051] In particular, the optical sensor 8 can detect, for example, that the conveyor belt 2 is filled with conveyed material 4. The optical signal (e.g., an image) can then be transmitted to the control unit 15. The control unit 15 can then evaluate the image information, and the weight G 1-n of the conveyed material 4 at the detected location (in the specific section T 1-n of the conveyor belt 2) can be determined through appropriate analysis. For this, the specific gravity of the conveyed material is, of course, also necessary. This specific gravity can be pre-stored in a memory location (not shown) of the control unit 15.

[0052] The control unit 15 can then infer corresponding elongations or lengths L 1-n of the conveyor belt 2 along the conveyor line 19 and control the actuators 6 accordingly.

[0053] In the Fig. 3The figure illustrates the possibility of determining a distance D using an exemplary distance sensor 20. This distance D can be determined between a top surface 18 of the drive belt 12 and a top edge 17 of a tooth profile 14 of the conveyor belt 2 via the distance sensor 20 and / or a detection unit (not shown). This detection unit or the distance sensor 20 can transmit the corresponding detection signal regarding the distance D to the control unit 15. The control unit 15 can then compare the determined distance D with a pre-stored limit distance DLimit and, if the determined distance D is greater than the limit distance DLimit, conclude that the synchronization between the drive belt 12 and the conveyor belt 2 needs to be improved.This can be achieved, for example, by controlling the actuator 6 of the conveyor drive system 5 via the control unit 15 in such a way that a distance D is established which is smaller than the limit distance DLimit. In summary, the present invention optimally provides a method for the controlled drive of a steep conveyor and a method for controlling a steep conveyor, enabling precise engagement of the coupling profiles 13 with the tooth profiles 14, thereby minimizing wear on the drive elements and extending the service life of these components. Furthermore, the lowest possible friction can be ensured. These are very important factors in such conveyor systems, as repairs can only be carried out with considerable effort and extended downtime.

Claims

1. A device for controlled driving of a steep conveyor, comprising a control unit (15), a conveyor drive system (5) for driving a conveyor belt (2); and a sensor unit (8) for determining a weight G1-n of the material (4) to be conveyed, assigned to a predetermined section T1-n of the conveyor belt (2), wherein the sensor unit is configured to transmit information about the weight to the control unit (15), characterized in that the control unit (15) is configured to determine from the information about the weight G1-n a length L1-n assigned to the predetermined section T1-n in a steep conveyor region S of the conveyor belt (2), and based on the determined lengths L1-n assigned to the predetermined sections T1-n adjust a strain of a drive belt (2) of the conveyor drive system (5), wherein the strain of the drive belt (2) is adjusted via an actuator (6) of the conveyor drive system (5) by the control unit matching a distance B of coupling profiles (13) of the drive belt (12) engaging in tooth profiles (14) of the conveyor belt (2) with distances A of the tooth profiles (14), or by the control unit matching a distance B of tooth profiles (14) of the drive belt (12) engaging in coupling profiles (13) of the conveyor belt (2) with distances A of the coupling profiles (13).

2. The device according to claim 1, wherein the actuator (6) for adjusting the strain of the drive belt (12) and thus a distance B from coupling profiles (13) of the drive belt (12) adjusts a center distance C from deflection rollers (16) of the drive belt (12) and / or applies a corresponding strain force to the drive belt (12) via an additional roller.

3. The device according to at least one of the preceding claims, wherein the sensor unit includes a weighing device (9) which transmits the weight to the control unit (15).

4. The device according to at least one of the preceding claims, wherein the sensor unit (8) includes an optical sensor which transmits information about a filling quantity with material to be conveyed (4) to the control unit (15) and the control unit (15) is configured to determine a weight from this information.

5. The device according to at least one of the preceding claims, wherein the sensor unit (8) includes an ultrasonic or X-ray sensor which transmits information about a filling quantity with material to be conveyed (4) and / or specific weight of the material to be conveyed (4) to the control unit (15) and the control unit (15) is configured to determine a weight from this information.

6. The device according to at least one of the preceding claims, wherein signal transmitters (10) are provided on the conveyor belt (2) at predetermined distances in the longitudinal direction of the conveyor line (19), the position signals of which signal transmitters are detected by a position sensor (11) which transmits position information to the control unit (15), wherein the control unit (15) is configured to assign the weight G1-n of the material to be conveyed (4) to the predetermined sections T1-n on the basis of the position information.

7. The device according to claim 6, wherein the signal transmitter (10) is configured as an optical signal transmitter, as a mechanical signal transmitter, as an electromagnetic signal transmitter and / or as an X-ray source.

8. The device according to at least one of the preceding claims, wherein the control unit (15) is configured to determine, on the basis of the weight information in the predetermined sections T1-n, the lengths L1-n and / or elongations of the conveyor belt (2) assigned to the sections T1-n, in particular along a steep conveyor section region S or individual positions on the steep conveyor section region S.

9. The device according to claim 8, wherein the control unit (15) is configured to determine the lengths L1-n and / or elongations of the conveyor belt (2) assigned to the sections T1-n via the dead weight of the conveyor belt (2), the detected or determined weight G1-n of the material to be conveyed (4), the E-modules of the conveyor belt (2) assigned to the conveyor belt section(s), a pretension of the conveyor belt (2) and / or the inclinations of the steep conveyor section region S.

10. The device according to claim 1, wherein the control unit (15) is configured to implement the determined lengths L1-n into distances A1-n from tooth profiles (14) of the conveyor belt (2), and substantially match or synchronize a distance B of coupling profiles (13) of the drive belt (12) engaging in the tooth profiles (14) with the distances A1-n or an at least double separation thereof by adapting the strain of the drive belt (12) accordingly via the actuator (6) of the conveyor drive system (5).

11. The device for steep conveyors according to at least one of the preceding claims, wherein the control unit (15) is configured to determine the elongation or length L1-n of the conveyor belt (2) in an elastic region caused by the weight force of the conveyor belt (2) and the weight of the material to be conveyed (4) in the steep conveyor section region S and to substantially match the distance B of the coupling profiles (13) of the drive belt (12) with the distances A1-n of the tooth profiles (14) by a corresponding elastic strain of the drive belt (12) via the actuator (6).

12. The device for steep conveyors according to at least one of the preceding claims, wherein the control unit (15) is configured to determine via a detection unit a distance D between an upper edge (17) of the tooth profile (14) and an upper side (18) of the drive belt (12) and to use the distance D as a fed-back controlled variable for adjusting the required strain of the drive belt (12) and thus the distances B of the coupling profiles (13), wherein the strain is adapted accordingly when a predetermined limit distance Dlimit is exceeded.

13. A method for controlling a steep conveyor, comprising the steps of: determining a weight G1-n of a material to be conveyed (4) via a sensor unit assigned to a predetermined section T1-n of the conveyor belt (2), wherein the sensor unit is configured to transmit information about the weight G1-n to a control unit (15), characterized in that said method further comprises the steps of determining a length L1-n assigned to the predetermined section T1-n in a steep conveyor section S of the conveyor belt (2) from the information about the weight G1-n by the control unit (15), and adjusting a strain of a drive belt (12) of a conveyor drive system (5) based on lengths L1-n assigned to predetermined sections T1-n, wherein the strain of the drive belt (2) is adjusted via an actuator (6) of the conveyor drive system (5) by matching a distance B of coupling profiles (13) of the drive belt (12) engaging in tooth profiles (14) of the conveyor belt (2) with distances A of the tooth profiles (14) or by matching a distance B of tooth profiles (14) of the drive belt (12) engaging in coupling profiles (13) of the conveyor belt (2) with distances A of the coupling profiles (13).