Conveyor belt operation monitoring system

Abstract

To provide a conveyor belt operation monitoring system configured to collect data regarding belt operation conditions so as to observe the conditions and prevent more serious failure in belt operation.SOLUTION: The invention relates to a sensor assembly for a conveyor belt. The assembly comprises: one or more sensors 1630-1645 configured to be integrated with the conveyor belt and collect data regarding belt operating conditions; and an on-board controller 1605 including a device processor 1610 and a non-transient computer readable medium 1612. The computer readable medium 1612 stores instructions, executable by the device processor 1610, therein to perform functions of receiving data from the one or more sensors 1630-1645 and transmitting the data to an off-board controller 1700.SELECTED DRAWING: Figure 16

Description

[Technical field]

[0001] The present disclosure (hereinafter the invention may be referred to as the "disclosure") relates to a conveyor belt operation monitoring system, and more particularly to a conveyor system having one or more built-in sensors integral to the belt and at least one external data receiving module. [Background technology]

[0002] Conveyor belts often operate in harsh conditions, including high and / or low temperatures, moisture, dust, and / or debris. Additionally, the complexity of the belt path can increase operational difficulties. Also, addressing malfunctions during belt operation can be costly, time consuming, and generally inconvenient. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Pat. No. 9,884,723 Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure is directed to systems and methods for addressing one or more of the problems set forth above. [Means for solving the problem]

[0005] The disclosed system is configured to collect data on belt operating conditions in order to observe trends and prevent more serious belt operating failures. To that end, the system includes one or more on-board sensors integral to the belt and at least one external data receiving module. For example, the disclosed system includes at least one on-board sensor assembly that includes various sensors including a tension sensor (load cell), a gyro sensor configured to detect belt angle in three axes, and an acceleration sensor configured to detect belt acceleration along the same three axes. The disclosed system is configured to collect data with these on-board sensors and then transmit the data to an offboard controller for processing. Anomalies can be detected and a warning / alarm can be issued so that steps can be taken to mitigate the problem causing the anomaly.

[0006] In one aspect, the present disclosure is directed to a sensor assembly for a conveyor belt, the sensor assembly including a load cell mountable to a link of a modular conveyor belt and configured to measure tension in the belt, and a housing, the housing may include a first cavity configured to receive at least a portion of the load cell and a second cavity configured to receive one or more electronic components.

[0007] In another aspect, the disclosure is directed to a tension sensing system for a conveyor belt, the tension sensing system including a first link pivotally connectable to another link of the conveyor belt and a sensor assembly attached to the first link. The sensor assembly may include a load cell attachable to the first link and configured to measure tension in the belt, and a housing having a first cavity configured to receive at least a portion of the load cell.

[0008] In another aspect, the present disclosure is directed to a conveyor belt comprising a plurality of links connected by a plurality of connecting rods and including at least a first link, and a sensor assembly attached to the first link, the sensor assembly including a load cell attachable to the first link and configured to measure tension in the belt, and a housing having a first cavity configured to receive at least a portion of the load cell.

[0009] In another aspect, the present disclosure is directed to a sensor assembly for a conveyor belt comprising one or more sensors configured to be integral with the belt and to collect data regarding belt operating conditions, and an onboard controller including a device processor and a non-transient computer readable medium having instructions stored therein executable by the processor to perform the functions of receiving data from the one or more sensors and transmitting data to an external controller.

[0010] In another aspect, the present disclosure is directed to a receiver module for a conveyor belt data collection system comprising a housing configured to be positioned external to and in proximity to the belt, and a belt interface unit including an external controller including a device processor and a non-transitory computer readable medium having instructions stored therein executable by a processor to perform the function of receiving data regarding belt operating conditions transmitted by an internal controller integral with the belt.

[0011] In another aspect, the present disclosure is directed to a conveyor belt operation monitoring system comprising one or more sensors integrated with the belt and configured to collect data regarding belt operating conditions, and an on-board controller including a first device processor and a first non-transitory computer readable medium, the computer readable medium having instructions executable by the processor stored therein to perform the functions of receiving data from the one or more sensors and transmitting the data to an external controller, the at least one receiving module including a belt interface unit, the belt interface unit including a second device processor and a second non-transitory computer readable medium having instructions executable by the processor stored therein to perform the functions of receiving data transmitted by the on-board controller.

[0012] Other systems, methods, features, and advantages of the present disclosure will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of this disclosure, and be protected by the following claims.

[0013] The present invention can be better understood with reference to the following drawings and description. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the drawings, like reference numerals indicate corresponding parts throughout the different views. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 is a schematic diagram showing the appearance of a spiral conveyor system according to an embodiment. [Diagram 2] FIG. 2 is a schematic exploded view showing an on-board sensor assembly for a conveyor belt. [Diagram 3] FIG. 3 is a second schematic perspective view of the built-in sensor assembly shown in FIG. 2. [Figure 4] FIG. 3 is a schematic perspective view of an electronics housing of the sensor assembly shown in FIG. 2. [Diagram 5] 5 is a second schematic perspective view of the electronic device housing shown in FIG. 4. [Figure 6] FIG. 5 is a third schematic perspective view of the electronic device housing shown in FIG. [Figure 7] FIG. 3 is a schematic perspective view of an electronics pod with built-in sensor assembly shown in FIG. 2. [Figure 8] FIG. 3 is a schematic exploded view of a link and load cell assembly of the on-board sensor assembly shown in FIG. 2. [Figure 9] FIG. 13 is another schematic exploded view showing the link and load cell assembly. [Figure 10] FIG. 3 is a schematic perspective view showing a link portion of the assembly shown in FIG. 2. [Figure 11] FIG. 2 is a second schematic diagram of a link. [Figure 12] FIG. 3 is a third schematic diagram of a link. [Figure 13] FIG. 4 is a fourth schematic diagram of a link. [Figure 14] FIG. 3 is a schematic perspective view showing a load cell of the sensor assembly shown in FIG. 2. [Figure 15] FIG. 2 is another schematic diagram of a load cell. [Figure 16] FIG. 2 is a block diagram showing components included in a data collection system according to an embodiment. [Figure 17] FIG. 2 is a block diagram showing external components of the data collection system. [Figure 18] 4 is a flow chart illustrating a method for monitoring belt tension. [Figure 19] 4 is a flow chart illustrating a method for monitoring a belt angle. [Figure 20] 4 is a flow chart illustrating a method for monitoring belt acceleration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] For clarity, the detailed description herein describes a specific exemplary embodiment. A positive drive spiral conveyor system is shown. However, the disclosure of this application is applicable to any suitable conveyor system. That is, the disclosed sensor arrangements / systems may be implemented in non-positive drive and non-spiral systems.

[0016] The spiral conveyor systems discussed below are generally referred to as positive drive systems, in which a drive element is in direct contact with the conveyor belt to propel it in the direction of travel. In the systems discussed below, a central rotating drum includes a drive element that includes a drive surface for engaging the conveyor belt. The drive element's drive surface may be adjacent to a contoured surface of the drive element, such as ribs that protrude from the drum or surface of the drive element. The ribs may impart an improved shape to the drive surface and may smooth movement of the conveyor belt up and down the spiral, particularly when the ribs themselves have varying heights above the drum surface. The conveyor belt may also include provisions to enhance engagement with the ribs, such as protrusions or tabs with flat surfaces for better contact with the drive surface.

[0017] FIG. 1 illustrates an embodiment of a helical conveyor system 1 utilizing at least one contoured drive element drive system. Helical conveyor systems such as helical conveyor system 1 are known in the art. Helical conveyor system 1 may include a conveyor belt 15 configured to move a helical column 5 around a drive drum 10. In some embodiments, drive drum 10 may include one or more drive elements 20 that engage conveyor belt 15 for a forward drive system, where frictional and / or geometric engagement of drive elements 20 with conveyor belt 15 imparts forward motion to conveyor belt 15. In some embodiments, the drive drum 10 and edges of conveyor belt 15 may include provisions for engaging one another to transfer drive from the wheel drum to the conveyor belt.

[0018] The drum 10 may be configured to rotate at a variety of RPMs (revolutions per minute), but may also be configured to turn at a low RPM. The exact speed may depend on factors such as the height of the spiral column 5, the length of the belt 15, and the intended use of the system, such as establishing a particular cooking, baking, or freezing time. In some embodiments, the drum 10 may turn at 15 RPM or less. In some embodiments, the drum 10 may turn at 10 RPM or less. In some embodiments, the drum 10 may turn at 4 RPM or less. In some embodiments, the drum 10 may turn at a speed between 0.1 RPM and 10 RPM inclusive.

[0019] The drum 10 may be rotated using any method known in the art, such as by a motor (not shown) located near the base 103 of the spiral conveyor system 1. The motor may transmit the force it generates to the drum 10 using any mechanism known in the art.

[0020] In some embodiments, such as the embodiment shown in FIG. 1, there may be a known system, such as a chain and gearbox, for controlling the transmission of force from the motor to the shaft 106. The shaft 106 may be any type of drive shaft known in the art, such as a long metal pole that extends from the base 103 to the top of the helical column 5 along the drum central axis 3. One or more poles, such as pole 109, may attach the shaft 106 to the drum 10 and transmit the rotational force of the shaft 106 to the drum 10. The drum 10 may be generally cylindrical in shape and, in some embodiments, may have a cylindrical surface. The cylindrical surface may be a continuous cylindrical drum surface formed of sheet metal, or may have a discontinuous surface formed of individual vertical drive elements that extend between and connect circular support bands arranged around the drum central axis, or may be a combination of sheet metal and vertical bars as shown in FIG. 1.

[0021] Other configurations are envisioned to provide a suitable cylindrical surface for guiding the inner edge of belt 15 through helical column 5. Drive element 20 may comprise ribs attached to the sheet metal surface of a drum as in the embodiment shown in Figure 1, or attached to a cage bar, for example where the ribs extend from the surface of a cage bar cap. Drive element 20 may also comprise a cap or coating to provide a contoured surface and / or improve wear characteristics, etc.

[0022] A bottom bearing 101 may be provided in, on, or in association with the motor, gearbox, and / or conveyor frame. As is known in the art, the bottom bearing 101 is provided to support radial and axial loads while reducing rotational friction between the motor and / or base 103 and shaft 106. Bearings and their functionality are generally known and understood in the art.

[0023] Conveyor belt 15 may be modular and may include links and connecting rods. An exemplary modular belt implementing links and connecting rods is described and discussed in US Patent Application Publication No. 2013 / 0133999, issued Feb. 6, 2018 to Neely et al. and entitled Spiral Conveyor System, the entirety of which is incorporated herein by reference.

[0024] Conveyor belt 15 may be any type of endless belt known in the art. Conveyor belt 15 may be made of metals, plastics, composites, ceramics, combinations of these materials, or any other type of conveyor belt material known in the art. The particular material may be selected based on factors such as temperature exposure (baking, freezing, room temperature transfer), tension required, belt length, ability to clean and / or sterilize the belt, etc.

[0025] 1, the belt 15 may be an upgoing belt, where the belt 15 moves from the bottom 64 of the spiral column 5 to the top 63 of the spiral column 5. In other embodiments, the direction of movement may be down, where the belt 15 moves from the top 63 to the bottom 64. The belt paths at the top 63 and bottom 64 may be aligned as shown, or may be angled relative to one another about the central axis 3 of the drum 10.

[0026] In use, the conveyor belt 15 enters one end of the drum 10 (usually the bottom 64). The conveyor belt 15 may exit two rollers or sprockets located on a mandrel and be fed into the system 1. The conveyor belt 15 travels through stacked spiral stages around the central drum 10. The conveyor belt 15 then exits the other end of the drum 10 (usually near the top 63). The conveyor belt 15 may be an endless belt 15, in which case the conveyor belt 15 is fed back onto the mandrel / sprocket at the other end of the drum 10 (e.g., in one embodiment the belt 15 exits the top 63 of the drum 10 and then travels back to the bottom 64 of the drum 10). However, in either embodiment the system may be ascending (moving from bottom to top) or descending (moving from top to bottom). Gearing and selective weighting of belt 15 at the entry and / or exit points of helix 5 may be configured to assist in controlling tension in belt 15 as it moves through system 1. For example, system 1 may include a take-up sprocket 115 configured to unwind belt 15 from helix column 5. Take-up sprocket 115 may be located at or after the first end roller. Take-up sprocket 115 may be independently driven, such as by a motor. In some embodiments, the motor may be a constant torque motor such that tension in belt 15 may be controlled within a desired range.

[0027] In some embodiments, a weighted take-up roller 117 may be provided to help maintain belt tension along the return path 104 and to remove belt slack from the system. Proper tensioning of the belt 15 may prevent operational problems such as slippage of the belt 15 on the drum 10, belt jumping, or difficulty feeding the belt 15 into or out of the helical stack.

[0028] In some embodiments, the first stage 80 of the belt 15 at the entry end (e.g., bottom 64) has a first larger diameter and the last stage of the belt 15 at the exit end has a second smaller diameter. For example, FIG. 1 shows two different stages (first stage 80 and second stage 90) of the belt 15 formed of links and elongated bars connecting the links to each other. The drum 10 may have a first diameter that supports the first stage 80 and a second smaller diameter that supports the second stage 90. The first diameter may be lower on the drum 10 than the second diameter. The belt 15 may be held at each diameter by engagement of a peripheral bearing surface of the belt 15 with a peripheral bearing surface of the drive element 20.

[0029] 1, the helix may include common support pillars, such as first pillar 111, second pillar 112, and third pillar 113. The helix may have any suitable number of pillars, which may be arranged as needed for a structurally stable construction.

[0030] Additionally, belt data collection system components may be incorporated into the belt path. For example, one or more sensor arrays may be incorporated into the belt to facilitate collection of data such as tension data, angle data, acceleration data, etc., as discussed in more detail below. As shown, the belt 15 may include at least one sensor assembly. As shown in FIG. 1, the system may include a first sensor assembly 140, a second sensor assembly 150, and a third sensor assembly 155. It will be understood that the belt may include any desired number of sensor assemblies, including a single sensor assembly or multiple sensor assemblies.

[0031] Additionally, one or more receiver modules may be positioned along the path of the belt system. For example, FIG. 1 shows three receiver modules, including a first receiver module 120, a second receiver module 125, and a third receiver module 130. It will be appreciated that the system may have any suitable number of receiver modules, including a single receiver module or multiple receiver modules. The number of receiver modules may be selected based on various factors, such as the overall dimensions of the belt system, the complexity of the belt system, the amount of data collected, etc. In some embodiments, multiple receiver modules may form a mesh network. The more sensor assemblies and receiver modules in the system, the more data can be collected, more frequently, and with a wider communication range.

[0032] Each receiver module may include a belt interface unit. For example, the first receiver module 120 may include a first belt interface unit 135. Additionally, the second receiver module 125 may include a second belt interface unit 145. The third receiver module 130 faces the opposite direction, and therefore the third belt interface unit is not shown in FIG. 1. It will be understood that the configuration and arrangement of the receiver modules and belt interface units depicted in FIG. 1 are schematic only. Those skilled in the art will recognize suitable configurations and arrangements of these components.

[0033] As the sensor assembly passes through the first belt interface unit 135, the system may perform various functions. For example, the belt interface unit may charge a power source in the sensor assembly via inductive charging. Alternatively, or in addition, the belt interface unit may receive data transmitted by the sensor assembly. It will be understood that all of the belt interface units in a given system may perform the same function. For example, in some cases, all of the belt interface units may perform the inductive charging function, but only a single belt interface unit may collect data. It will be understood that as many or as few of the belt interface units may perform the desired charging and / or data collection functions.

[0034] FIG 2 is a schematic exploded view of a self-contained sensor assembly for a conveyor belt. As shown in FIG 2, the sensor assembly 200 may include a link 205, a housing 210, and a load cell 215 attachable to the link 205 (e.g., with fastener 220) and configured to measure tension in the belt. The housing 210 includes a first cavity 225 configured to receive at least a portion of the load cell 215 and a second cavity 230 configured to receive one or more electronic components (shown in FIG 2 as an electronics pod 235). The sensor assembly 200 also includes an electronics cavity cover 240 that is removably attachable via a number of fasteners 245 (e.g., screws).

[0035] FIG. 3 is a second schematic perspective view of the self-contained sensor assembly shown in FIG. 2. As shown in FIG. 3, the sensor assembly 200 may be pivotally attached to other links of the belt via connecting rods. For example, a leading connecting rod 300 and a trailing connecting rod 305 are shown. The leading connecting rod 300 extends along a leading rod axis 310 and the trailing connecting rod extends along a trailing rod axis 315. The leading rod axis 310 and the trailing rod axis 315 extend substantially parallel to a horizontal axis 320 of the sensor assembly 200. However, it will be understood that the angle of the axis 310 may vary relative to the sensor assembly due to the oval / slotted openings at the leading ends of the sensor assembly components to allow the belt to turn.

[0036] As shown in FIG. 3, a vertical axis 325 extends perpendicular to the horizontal axis 320, and a major axis 330 extends in a front-to-rear direction, parallel to the direction of belt travel (indicated by arrow 335) and perpendicular to the horizontal axis 320 and the vertical axis 325.

[0037] Thus, a conveyor belt according to the present disclosure may include a plurality of links connected by a plurality of connecting rods, the plurality of links including at least a first link, and a sensor assembly attached to the first link.

[0038] As shown in FIG. 3, a first end of the load cell is attached to the lateral extension of the link 205 with a fastener 220, and a second end of the load cell includes an opening through which one of the connecting rods extends such that the load cell is configured to sense the extension of the second leg of the link due to tension in the conveyor belt.

[0039] Figure 4 is a schematic perspective view of the electronics housing of the sensor assembly shown in Figure 2. As shown in Figure 4, the housing 210 includes a leading side 400 and a driven side 405. Additionally, the housing 210 includes a first portion 410 configured to receive a load cell and a second portion 415 configured to receive an electronics pod.

[0040] FIG. 5 is a second schematic perspective view of the electronics housing shown in FIG. 4. As shown in FIG. 5, the housing 210 includes a through hole 500 configured to accommodate wiring between the load cell and the electronics pod. Additionally, the first portion 410 of the housing 210 includes a first guide rod opening 505 and a first follower rod opening 510. Additionally, the second portion 415 of the housing 210 includes a second guide rod opening 515 and a second follower rod opening 520. These four openings are configured to receive the connecting rods (see FIG. 3). As shown in FIG. 5, the first guide rod opening 505 and the second guide rod opening 515 may be oval / slotted to allow the belt to be a turn curve belt.

[0041] Figure 6 is a third schematic perspective view of the electronics housing shown in Figure 4. Figure 6 better illustrates the cavity 225, the through hole 500, the first guide rod opening 505 and the first follower rod opening 510.

[0042] 7 is a schematic perspective view of an electronics pod of the on-board sensor assembly shown in FIG. 2. As shown in FIG. 7, electronics pod 235 may include a sensor pack 700 that houses one or more sensors, such as electronics associated with a load cell, a gyro (angle) sensor, and / or an accelerometer. Additionally, electronics pod 235 includes at least one power source, such as a battery or a capacitor (also referred to as a capacitor). As shown in FIG. 7, electronics pod 235 includes a first capacitor 705 and a second capacitor 710.

[0043] Capacitors are advantageous over batteries for several reasons. First, capacitors can charge faster than batteries. Because the sensor assembly quickly passes the receiving module, there is a limited amount of time for inductive charging to occur. Thus, the capacitor maximizes the amount of charge that can be achieved in that short period of time. Second, capacitors discharge less than batteries at low temperatures. Since the disclosed conveyors can be utilized at low temperatures, the exceptional performance of capacitors at low temperatures is beneficial. The same is true at higher temperatures where capacitors are more stable than batteries. Again, capacitors have an advantage over batteries because the disclosed belt systems can be utilized in high temperature environments.

[0044] 8 is a schematic exploded view of the link and load cell assembly of the self-contained sensor assembly shown in FIG. 2. As shown in FIG. 8, the link 205 may be substantially U-shaped and includes a first leg 800, a second leg 805, and a connector 810 extending between the first leg 800 and the second leg 805. The link 205 also includes a first guide rod opening 815 and a first follower rod opening 820 in the first leg 800. The link 205 also includes a second guide rod opening (not shown) opposite the first guide rod opening 815 (see second guide rod opening 1005 in FIG. 10) and a second follower rod opening 825.

[0045] 8, the link 205 includes a lateral extension 830 having a cavity or receiver 835 configured to receive at least a portion of the load cell 215. Additionally, the lateral extension 830 includes a threading opening 840 configured to receive a fastener 220 (through a fastener opening 845 in the load cell 215) to secure the load cell 215 to the link 205.

[0046] 9 is another schematic exploded view of a link and load cell assembly. As shown in FIG 9, the link 205 is substantially U-shaped. As further shown in FIG 9, the load cell 215 includes a through hole 900.

[0047] Figure 10 is a schematic perspective view of the link portion of the assembly shown in Figure 2. As shown in Figure 10, the link 205 includes a recess 1000 configured to receive a connecting rod. Additionally, Figure 10 shows the second guide rod opening 1005 as described above. As shown, the second guide rod opening 1005 may be oval / slotted to allow the belt to be a turn curve belt.

[0048] A second schematic diagram of the link is shown in Figure 11. As shown in Figure 11, the connection portion 810 of the link 205 includes a groove 1100 on the driven side to accommodate the connecting rod. The groove 1100 stabilizes the assembly during belt operation.

[0049] Figure 12 is a third schematic diagram of the link. In Figure 12, the recess 1000 is better seen as well as the first follower rod opening 820 and the receiver 835. As shown in Figure 12, a portion of the first follower rod opening 820 and the receiver 835 may intersect.

[0050] FIG. 13 is a fourth schematic diagram of a link. Again, a U-shaped configuration of the link 205 is illustrated. Additionally, as shown in FIG. 13, the lateral extensions may be shorter than the overall length of the link 205. As shown, the overall length 1300 of the link 205 extends between the leading end 1305 and the trailing end 1310 of the link 205. The length 1315 of the lateral extensions 830 is made significantly shorter than the overall length 1300. With this arrangement, the guide connecting rod does not pass through the load cell, which provides a more stable strain measurement.

[0051] The load cell has a first end and a second end, where the first end includes an opening through which a fastener can be inserted for attaching the first end of the load cell to the body of the link, and the second end of the load cell has a second opening configured to receive a connecting rod of the belt.

[0052] Figure 14 is a schematic perspective view of a load cell of the sensor assembly shown in Figure 2. The load cell 215 may include the previously discussed fastener opening 845 at a leading end of the load cell 215 and a rod opening 1400 at a trailing end of the load cell 215. (See also Figures 8 and 9.) 15 is another schematic diagram of the load cell, which better shows the through hole 900 through the load cell 215.

[0053] FIG. 16 is a block diagram illustrating the internal components of a data collection system according to an exemplary embodiment. As shown in FIG. 16, the system may include an on-belt electronics pod 1600. In some embodiments, the pod 1600 may include tension sensor electronics 1630 associated with a load cell. In other embodiments, raw load cell data may simply be received by the electronics pod. Additionally, the pod 1600 may include a position sensor 1635 or electronics configured to facilitate locating the sensor assembly along the belt path. For example, in some embodiments, the system may use the belt speed and elapsed time (e.g., since the sensor assembly last passed a receiving module) to calculate how far the sensor assembly has progressed along the belt path at a given time.

[0054] Additionally, the pod 1600 includes a gyro sensor 1640 configured to sense the belt angle in three axes. For example, if the sensor assembly is sensed to be oriented at a non-horizontal angle about the long axis (the front-to-rear axis extending along the direction of belt travel), this may indicate that the belt is "jumping," where a portion of the belt may bounce upward from its proper horizontal position. Similarly, the pod 1600 includes an acceleration sensor 1645 configured to measure the belt acceleration along the same three axes. For example, sensing a variation in the belt acceleration along the long axis may indicate surging. Additionally, sensing the belt angle in the three axes and the belt acceleration along the three axes provides six values ​​that can be collectively analyzed to determine many other aspects of the belt operation.

[0055] The pod 1600 also includes one or more capacitors 1650. The capacitors 1650 may include any of the features described above with respect to the first capacitor 705 and the second capacitor 710.

[0056] Additionally, the pod 1600 may include an onboard controller 1605. The controller 1605 may include various computing and communication hardware, such as a server, circuitry, a display, etc. Additionally, the controller 1605 includes a device processor 1610 and a non-transitory computer readable medium 1615 that includes instructions executable by the device processor 1610 to perform the processes discussed herein, such as receiving and transmitting data.

[0057] The on-board components are configured to operate at a relatively low voltage. This allows the system to continue to operate when the charge on the capacitor is low, maximizing capacitor utilization. In some embodiments, the on-board controller is configured to function with a power supply ranging from about 0.1 to about 5.5 volts. In some embodiments, the on-board controller is configured to function with a power supply less than about 5.5 volts.

[0058] A non-transitory computer readable medium may include any suitable computer readable medium, such as memory (e.g., RAM, ROM, flash memory, or any other type of memory known in the art). In some embodiments, a non-transitory computer readable medium may include, for example, electronic storage devices, magnetic storage devices, optical storage devices, electromagnetic storage devices, semiconductor storage devices, or any suitable combination of such devices. More specific examples of non-transitory computer readable media may include portable computer diskettes, floppy disks, hard disks, read only memory (ROM), random access memory (RAM), static random access memory (SRAM), portable compact disk read only memory (CD-ROM), erasable programmable read only memory (EPROM or flash memory), digital versatile disks (DVDs), memory sticks, and any suitable combination of these exemplary media. As used herein, a non-transitory computer readable medium should not be interpreted as a transitory signal, such as an electric wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a wave guide or other transmission medium (e.g., light pulses passing through a fiber optic cable), or an electric signal transmitted through an electrical wire.

[0059] The instructions stored on the non-transitory computer readable medium for carrying out the operations of the present invention may be instruction set architecture (ISA) instructions, assembler instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, configuration data for an integrated circuit, state-setting data, or source or object code written in any one of one or more programming languages, including object-oriented programming languages ​​such as Smalltalk, C++ or a suitable language, and procedural programming languages ​​such as the "C" programming language or a similar programming language.

[0060] Aspects of the disclosure are described in conjunction with figures illustrating flowcharts and / or block diagrams of methods, apparatus (systems) and computing products. It will be understood that each block of the flowcharts and / or block diagrams is implemented by computer readable instructions. The flowcharts and block diagrams in the figures illustrate the structure, functionality and operation of possible implementations of various disclosed embodiments. Thus, each block in the flowcharts or block diagrams may represent a module, segment, or portion of instructions. In some implementations, the functions described in the figures and claims may occur in an order alternate to that listed and / or illustrated.

[0061] The controller 1605 may include networking hardware configured to interface with other nodes of a network, such as a LAN, WLAN, or other network. Additionally, the controller 1605 may be configured to receive data from multiple sources and to communicate information to one or more external destinations. Thus, the controller 1605 may include a receiver 1620 and a transmitter 1625. (It will be appreciated that in some embodiments the receiver and transmitter may be combined in a transceiver.) Any suitable communication platform and / or protocol may be utilized for communication between the controller 1605 and other components of the system. Since the various sources of information may each have their own platform and / or protocol, the system may be configured to interface with each platform and / or protocol to receive data.

[0062] In some embodiments, the computer-readable medium 1615 of the controller 1605 includes instructions executable by the processor 1610 to receive data from one or more sensors and to transmit the data to an offboard controller 1700.

[0063] 17 is a block diagram illustrating the external components of the data collection system (i.e., components present in or otherwise associated with the receiving module). Similar to the internal controller 1605, the external controller 1700 may include a device processor 1705, a non-transitory computer readable medium 1710, a receiver 1715, and a transmitter 1720. The features and characteristics of the controller 1700 and its components may be similar to those described above with respect to the internal controller 1605.

[0064] It will be noted that the receiver module may also include an apparatus configured to inductively charge a power source contained within the belt as the belt passes the receiver module, i.e., the receiver module includes an inductive charging apparatus configured to inductively charge a capacitor in an electronics pod contained within the belt.

[0065] 17, an external controller 1700 may be configured to receive tension data 1725, position data 1730, gyro data 1735, and / or acceleration data 1740, all of which come from the internal controller 1605. The external controller 1700 may collect this data and perform one or more processing steps. For example, in some cases, the external controller may be configured to generate live readings 1745 of the collected data, or parameters determined based on the data. Such live readings may be generated via a screen or graphical user interface for a customer and / or system manufacturer.

[0066] Alternatively, or in addition, the external controller 1700 may be configured to make one or more comparisons between the data (1750). For example, current data can be compared to previously collected data to observe trends. Such trends may indicate wear or other malfunctions, allowing action to be taken before a malfunctioning belt leads to catastrophic failure.

[0067] Alternatively or additionally, the external controller 1700 may be configured to activate one or more alerts or warnings (1755) if a measured parameter falls outside a predetermined range. For example, an alert may be issued if belt tension is detected to be above a predetermined threshold so that the system can be checked. Similarly, an alert may be issued if belt angle and / or belt acceleration fall outside a predetermined range.

[0068] Since operational data is collected alongside position data, the thresholds may be dynamic instead of static. For example, due to the nature of a helical system, belt tension typically increases as the belt ascends the helix. Hence, the thresholds may be dynamic, with a lower tension needed to trigger an alert near the bottom of the helix and a higher tension needed to trigger an alert near the top of the helix. For similar reasons, the range of acceptable belt acceleration may also be dynamic. This is because the belt is expected to accelerate by different amounts and in different directions at different locations on the belt path. Additionally, with regard to belt angle, the belt not only moves horizontally, but also vertically and along slopes (in a helix), and in some cases even on rises (e.g., around corners), so the expected angle of the belt changes around the belt path. Thus, when considering the tolerance of a measured belt angle, a dynamic expectation is used as to what the angle should be.

[0069] Additionally, by collecting data about the belt path and recording where each piece of data is stored, a "fingerprint" of the system may be generated at any given time. In some cases, the entire fingerprint may be compared to previously stored fingerprints.

[0070] FIG. 18 is a flow chart illustrating a method for monitoring belt tension. It will be understood that the order of operations considered may vary somewhat. As shown in FIG. 18, position data is collected in step 1800 while belt tension is sensed in step 1805. The position data is downloaded / transmitted to an external controller in step 1810 and the measured tension is downloaded / transmitted to an external controller in step 1815. In some embodiments, tension data may be buffered before being transmitted externally. This reduces the amount of memory required for the overall collection of data. This reduces the size required for the electronics pod, which is beneficial in terms of implementation. For similar reasons, the system may also be configured to buffer other types of data before transmission.

[0071] At step 1820, a dynamic tension threshold is selected and at step 1825, an evaluation is made as to whether the measured tension exceeds the threshold at the corresponding location based on the collected position data. If yes, an alert is issued at step 1830 and the system continues to monitor the belt tension. If no, the system simply continues to monitor the belt operation.

[0072] FIG. 19 is a flow chart illustrating a method for monitoring belt angle. Similar to FIG. 18 above, position data is collected in step 1900 while belt angle is sensed in step 1905. The position data is then downloaded / transmitted externally in step 1910 and the angle data is downloaded / transmitted externally in step 1915. A dynamic angle threshold (i.e., acceptable range of angle values) is determined in step 1920 based on the position data and an evaluation is made in step 1925 as to whether the sensed angle falls within the acceptable range. It will be appreciated that this evaluation is made in all three axes. If the belt angle falls outside the expected range in any of the three axes, an alert is issued in step 1930.

[0073] Figure 20 is a flow chart illustrating a method for monitoring belt acceleration. Position data is collected in step 2000, while belt acceleration is sensed in step 2005. The position data is then downloaded / transmitted externally in step 2010, and the angle data is downloaded / transmitted externally in step 2015. A dynamic acceleration threshold (i.e., an acceptable range of acceleration values) is determined in step 2020 based on the position data, and an evaluation is made in step 2025 as to whether the sensed acceleration falls within the acceptable range. It will be appreciated that this evaluation is made in all three axes. If the belt acceleration falls outside the expected range along any of the three axes, an alert is issued in step 2030.

[0074] The embodiments discussed herein may use methods and systems in artificial intelligence to improve the efficiency and effectiveness of the disclosed systems. As used herein, "artificial intelligence" may include machine learning and any methods known in the related art. By way of example, artificial intelligence may include systems and methods used in deep learning and machine vision.

[0075] While various embodiments have been described, the description is intended to be illustrative rather than restrictive, and many more embodiments and implementations are possible that are within the scope of the present embodiments, as will be apparent to those skilled in the art. Many possible combinations of features have been illustrated in the accompanying drawings and discussed in this detailed description, and many other combinations of the disclosed features are possible. Unless specifically controlled, any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment. Thus, it will be understood that any of the features shown and / or discussed in this disclosure may be implemented together in any suitable combination. The present embodiments are therefore to be controlled only in light of the appended claims and their equivalents. Various modifications and variations can also be made within the scope of the appended claims.

Claims

1. 1. A sensor assembly for a conveyor belt, comprising: one or more sensors integrated with the conveyor belt and configured to collect data regarding the operating conditions of the belt; a device processor and an embedded controller including a non-transitory computer readable medium; The computer-readable medium has stored therein instructions executable by a processor to perform the functions of receiving data from one or more sensors and transmitting the data to an external controller. Sensor assembly.

2. The sensor assembly of claim 1 , wherein the data relating to belt operating conditions includes belt tension data.

3. The sensor assembly of claim 1 , wherein the computer readable medium further comprises instructions for storing the tension data in a buffer prior to transmitting the tension data to the external controller.

4. The sensor assembly of claim 1 , wherein the data relating to belt operating conditions includes belt angle data.

5. The sensor assembly of claim 4 , wherein the data regarding belt operating conditions includes belt angle data about three different axes.

6. The sensor assembly of claim 1 , wherein the data relating to belt operating conditions includes belt acceleration data.

7. The sensor assembly of claim 6 , wherein the data relating to belt operating conditions includes belt acceleration data along three different axes.

8. The sensor assembly of claim 6 , wherein the on-board controller is configured to function with a power supply in the range of about 0.1 to about 5.5 volts.

9. 10. The sensor assembly of claim 1 or claim 8, wherein the on-board controller is configured to function with a power supply in the range of less than about 5.5 volts.

10. 1. A receiver module for a conveyor belt data collection system, comprising: a housing configured to be positioned external to and adjacent to the conveyor belt; a belt interface unit including an external controller having a device processor and a non-transitory computer readable medium storing instructions executable by the device processor; The instructions implement a receiver module that receives data regarding belt operating conditions transmitted by an internal controller associated with the belt.

11. 11. The receiver module of claim 10, further comprising a device configured to inductively charge a power source embedded in the belt as the belt passes through the receiver module.

12. 11. The receiver module of claim 10, wherein the data relating to belt operating conditions includes belt tension data.

13. The computer readable medium further includes instructions for activating an alert when the tension data exceeds a predetermined threshold; 13. The receiver module of claim 12, wherein the predetermined threshold is a dynamic threshold that varies depending on the location along the path of the conveyor belt where the tension data is collected.

14. 11. The receiver module of claim 10, wherein the data relating to belt operating conditions includes belt angle data.

15. 15. The receiver module of claim 14, wherein the data regarding belt operating conditions includes belt angle data about three different axes.

16. The computer readable medium further includes instructions for activating an alert if the belt angle data falls outside a predetermined range; 15. The receiver module of claim 14, wherein the predetermined range is a dynamic range that changes depending on the location at which the belt angle data is collected along a path of the conveyor belt.

17. 11. The receiver module of claim 10, wherein the data relating to belt driving conditions includes belt acceleration data.

18. 20. The receiver module of claim 17, wherein the data relating to belt driving conditions includes belt acceleration data along three different axes.

19. The computer readable medium further includes instructions for activating an alert if the belt acceleration data falls outside a predetermined range; 20. The receiver module of claim 17, wherein the predetermined range is a dynamic range that changes depending on the location along the path of the conveyor belt where the belt acceleration data is collected.

20. A conveyor belt operation monitoring system, comprising: one or more sensors integrated with the belt and configured to collect data regarding belt operating conditions; a first device processor and an embedded controller including a first non-transitory computer readable medium storing instructions executable by the processor; The instructions include receiving data from the one or more sensors; and Transmitting the data to an external controller; The conveyor belt operation monitoring system further includes at least one receiving module having a belt interface unit including a second device processor and an external controller including a second non-transitory computer readable medium, the instructions implementing the function of receiving the data transmitted by the internal controller.

21. 21. The system of claim 20, wherein two or more receiving modules are provided around the path of the belt.

22. 22. The system of claim 21, wherein the system includes a mesh network of receiving modules.

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