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 sometimes 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 belt-integrated built-in sensors and at least one external data receiving module.

Background Art

[0002] Conveyor belts are often operated under severe conditions including high and / or low temperatures, moisture, dust, and / or debris. In addition, the complexity of the belt path can also increase the difficulty of operation. Also, dealing with problems during belt operation can be costly, time-consuming, and generally inconvenient.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present disclosure is directed to systems and methods for addressing one or more of the problems described above.

Means for Solving the Problems

[0005] The system disclosed herein is configured to collect data on belt operation conditions in order to observe trends and prevent more serious belt malfunctions. For this purpose, the system includes one or more belt-integrated built-in sensors and at least one external data receiving module. For example, the system disclosed includes at least one built-in sensor assembly that includes various sensors, including a tension sensor (load cell), a gyro sensor configured to detect belt angles along three axes, and an accelerometer configured to detect belt acceleration along the same three axes. The system disclosed is configured to collect data from these built-in sensors and then transmit the data to an external controller (offboard controller) for processing. It can detect anomalies and issue warnings / alarms so that procedures can be taken to mitigate the problem causing the anomaly.

[0006] In one aspect, the disclosure is directed to a sensor assembly for a conveyor belt, comprising a load cell configured to measure the tension of a modular conveyor belt and attached to a link of the conveyor 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 present disclosure is directed toward a tension sensing system for a conveyor belt, comprising a first link rotatably connected to other links of the conveyor belt, and a sensor assembly attached to the first link. The sensor assembly may include a load cell that is attachable to the first link and configured to measure the tension of 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, comprising a load cell that is attachable to the first link and configured to measure the tension of 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 disclosure is directed to a sensor assembly for a conveyor belt, comprising one or more sensors configured to be integrated with the belt and to collect data relating to the belt's operating conditions, and an onboard controller including a device processor and a non-transient computer-readable medium. The computer-readable medium stores instructions executable by the processor in order to perform the functions of receiving data from one or more sensors and transmitting data to an external controller.

[0010] In another aspect, the disclosure is directed to a receiver module for a conveyor belt data acquisition system, comprising a housing located outside and near the conveyor belt, and a belt interface unit including an external controller including a device processor and a non-temporary computer-readable medium. The computer-readable medium stores instructions executable by the processor in order to perform the function of receiving data on belt operation conditions transmitted by an internal controller integrated with the belt.

[0011] In another aspect, the disclosure is directed to a conveyor belt operation monitoring system comprising one or more sensors configured to be integrated with the belt and to collect data relating to the belt operation conditions, and an internal controller including a first device processor and a first non-temporary computer-readable medium. To perform the functions of receiving data from one or more sensors and transmitting data to an external controller, the computer-readable medium stores therein instructions executable by the processor, and at least one receiving module includes a belt interface unit, the belt interface unit includes an external controller including a second device processor and a second non-temporary computer-readable medium, which stores therein instructions executable by the processor to perform the function of receiving data transmitted by the internal controller.

[0012] Other systems, methods, features, and advantages of this disclosure will become apparent to those skilled in the art by examining the following drawings and detailed description. All such additional systems, methods, features, and advantages are intended to be included in this description and abstract, within the scope of this disclosure, and protected by the following claims.

[0013] The present invention can be better understood by referring to the following drawings and description. The components in the drawings are not necessarily isometric and are rather emphasized in order to illustrate the principles of the present invention. Furthermore, in the drawings, similar reference numerals indicate corresponding parts across different drawings. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic diagram showing the external appearance of a helical conveyor system according to an embodiment. [Figure 2] This is a schematic exploded view showing an internal sensor assembly for a conveyor belt. [Figure 3] It is a second schematic perspective view showing the built-in sensor assembly shown in FIG. 2. [Figure 4] It is a schematic perspective view showing the electronic device housing of the sensor assembly shown in FIG. 2. [Figure 5] It is a second schematic perspective view of the electronic device housing shown in FIG. 4. [Figure 6] It is a third schematic perspective view of the electronic device housing shown in FIG. 4. [Figure 7] It is a schematic perspective view of the electronic device pod of the built-in sensor assembly shown in FIG. 2. [Figure 8] It is a schematic exploded view of the link and load cell assembly of the built-in sensor assembly shown in FIG. 2. [Figure 9] It is another schematic exploded view showing the link and load cell assembly. [Figure 10] It is a schematic perspective view showing the link portion of the assembly shown in FIG. 2. [Figure 11] It is a second schematic view of the link. [Figure 12] It is a third schematic view of the link. [Figure 13] It is a fourth schematic view of the link. [Figure 14] It is a schematic perspective view showing the load cell of the sensor assembly shown in FIG. 2. [Figure 15] It is another schematic view of the load cell. [Figure 16] It is a block diagram showing the built-in components of the data collection system according to the embodiment. [Figure 17] It is a block diagram showing the external components of the data collection system. [Figure 18] It is a flowchart explaining a method for monitoring belt tension. [Figure 19] It is a flowchart explaining a method for monitoring belt angle. [Figure 20] It is a flowchart explaining a method for monitoring belt acceleration. [Modes for carrying out the invention]

[0015] For clarity, the detailed description herein describes specific exemplary embodiments. A positive-drive spiral conveyor system is shown. However, the disclosures of this application are applicable to any suitable conveyor system; that is, the disclosed sensor array / system may be implemented in non-positive-drive and non-spiral systems.

[0016] The helical conveyor systems discussed below are generally forward-driven systems, in which a drive element directly contacts the conveyor belt to propel it in the direction of movement. In the systems discussed below, a central rotating drum includes a drive element with a drive surface for engaging with the conveyor belt. The drive surface of the drive element may be adjacent to a contoured surface of the drive element, such as a rib protruding from the drum or surface of the drive element. The rib may provide an improved shape to the drive surface and may smooth the movement of the conveyor belt up and down the helix, especially when the rib itself has varying heights above the drum surface. The conveyor belt may also include features that enhance engagement with the rib, such as projections or knobs with flat surfaces for better contact with the drive surface.

[0017] Figure 1 shows an embodiment of a helical conveyor system 1 utilizing a contoured drive element drive system. Helical conveyor systems, such as helical conveyor system 1, are well 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, the drive drum 10 may include one or more drive elements 20 that engage with the conveyor belt 15 for a forward drive system, wherein the frictional and / or geometric engagement of the drive elements 20 with the conveyor belt 15 imparts forward movement to the conveyor belt 15. In some embodiments, the drive drum 10 and the edges of the conveyor belt 15 may include provisions for engaging with each other to transmit driving force from the rotary drum to the conveyor belt.

[0018] The drum 10 may be configured to rotate at various RPMs (revolutions per minute), or it may be configured to turn at low RPMs. The exact speed may depend on factors such as the height of the helical column 5, the length of the belt 15, and the intended use of the system, such as establishing specific cooking, baking, or freezing times. 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 speeds between 0.1 RPM and 10 RPM (including both ends).

[0019] The drum 10 may be rotated using any method known in the art, such as a motor (not shown) located near the base 103 of the helical 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 Figure 1, a known system, such as a chain and gearbox, may be provided to control 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 column extending along the drum's central axis 3 from the base 103 to the top of the helical column 5. One or more supports, such as a support column 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 substantially 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 it may have a discontinuous surface formed of individual vertical drive elements that extend between circular support bands arranged around the drum's central axis and connect the circular support bands, or it may be a combination of sheet metal and a vertical bar, as shown in Figure 1.

[0021] Consider other structures for providing a suitable cylindrical surface to guide the inner edge of the belt 15 through the helical column 5. The drive element 20 may include ribs attached to the sheet metal surface of the drum, as in the embodiment shown in Figure 1, or attached to a cage bar, for example, on which the ribs extend from the surface of the cage bar cap. The drive element 20 may also include a cap or covering to provide a contoured surface and / or to improve wear characteristics, etc.

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

[0023] The conveyor belt 15 may be modular and may include links and connecting rods. An exemplary modular belt incorporating links and connecting rods is described and discussed in Patent Document 1 (Neely et al., published February 6, 2018, titled Spiral Conveyor System), which is incorporated herein by reference in its entirety.

[0024] The conveyor belt 15 may be any type of endless belt known in the art. The conveyor belt 15 may be made of metal, plastic, composite material, ceramic, a combination of these materials, or any other type of conveyor belt material known in the art. The specific material may be selected based on factors such as temperature exposure (baking, freezing, room temperature transmission), required tension, belt length, and the ability to clean and / or sterilize the belt.

[0025] In some embodiments, such as the one shown in Figure 1, the belt 15 may be an upgoing belt, moving from the bottom 64 of the helical column 5 to the top 63 of the helical column 5. In other embodiments, the direction of movement may be downward, with the belt 15 moving from the top 63 to the bottom 64. The belt paths at the top 63 and bottom 64 may be aligned as shown, or they may be arranged at angles to each other around the central axis 3 of the drum 10.

[0026] During use, the conveyor belt 15 enters one end of the drum 10 (usually the bottom 64). The conveyor belt 15 may exit through two rollers or sprockets positioned on a spindle and be supplied to the system 1. The conveyor belt 15 moves around the central drum 10 through stacked helical steps. The conveyor belt 15 then exits at 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 supplied back to the spindle / sprocket at the other end of the drum 10 (for example, in one embodiment, the belt 15 exits at the top 63 of the drum 10 and then moves back to the bottom 64 of the drum 10). However, in any embodiment, the system may be moving upward (from bottom to top) or downward (from top to bottom). The gearing and selective weighting of the belt 15 at the entry and / or exit points of the helical column 5 may be configured to help control the tension in the belt 15 as it moves through the system 1. For example, the system 1 may include a take-up sprocket 115 configured to pull the belt 15 out of the helical column 5. The take-up sprocket 115 may be located on or after the first end roller. The take-up sprocket 115 may be driven independently, such as by a motor. In some embodiments, the motor may be a constant-torque motor so that the tension of the belt 15 can be controlled within a desired range.

[0027] In some embodiments, a weighted winding roller 117 may be provided to help maintain belt tension along the return path 104 and to eliminate belt slack from the system. Appropriate tension on the belt 15 may prevent operational problems such as belt slippage against the drum 10, belt bouncing, or difficulty in feeding the belt 15 into or from the helical laminate.

[0028] In some embodiments, the first step 80 of the belt 15 at the entry end (e.g., bottom 64) has a first larger diameter, and the last step of the belt 15 at the exit end has a second smaller diameter. For example, Figure 1 shows two different steps (first step 80 and second step 90) of a belt 15 formed of links and elongated rods connecting the links to each other. The drum 10 may have a first diameter supporting the first step 80 and a second smaller diameter supporting the second step 90. The first diameter may be located lower on the drum 10 than the second diameter. The belt 15 may be held at each diameter by engagement of the support surface on the outer circumference of the belt 15 with the support surface on the outer circumference of the drive element 20.

[0029] As shown in Figure 1, the helix may include general support columns such as a first column 111, a second column 112, and a third column 113. The helix may have any appropriate number of columns, which can be arranged as needed for a structurally stable construction.

[0030] In addition, components of the belt data acquisition system may be incorporated into the belt path. For example, one or more sensor arrays may be incorporated into the belt to facilitate the collection of data such as tension data, angle data, and acceleration data, as will be discussed in more detail below. As illustrated, belt 15 may include at least one sensor assembly. As shown in Figure 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] In addition, one or more receiver modules may be positioned along the route of the belt system. For example, Figure 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 understood that the system may have any appropriate number of receiver modules, including a single receiver module or multiple receiver modules. The number of receiver modules may be chosen based on various factors, such as the overall dimensions of the belt system, the complexity of the belt system, and the amount of data to be collected. In some embodiments, multiple receiver modules may form a mesh network. The more sensor assemblies and receiver modules there are in the system, the more data can be collected, more frequently, and over 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. In addition, 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 Figure 1. It will be understood that the configuration and arrangement of the receiver modules and belt interface units depicted in Figure 1 are purely schematic. Those skilled in the art will recognize the appropriate configuration and arrangement 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 the power supply in the sensor assembly via electromagnetic induction charging. Alternatively, the belt interface unit may also receive data transmitted by the sensor assembly. It will be understood that all of a single belt interface unit may perform the same function in a given system. For example, in some cases, all belt interface units may perform the electromagnetic induction charging function, but only a single belt interface unit may collect data. It will be understood that as many or as few belt interface units as possible may perform the desired charging and / or data collection functions.

[0034] Figure 2 is a schematic exploded view of an internal sensor assembly for a conveyor belt. As shown in Figure 2, the sensor assembly 200 may include a link 205, a housing 210, and a load cell 215 that is attachable to the link 205 (e.g., by fasteners 220) and configured to measure the tension of 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 as an electronics pod 235 in Figure 2). The sensor assembly 200 also includes an electronics cavity cover 240 that is removablely attached via a number of fasteners 245 (e.g., screws).

[0035] Figure 3 is a second schematic perspective view of the built-in sensor assembly shown in Figure 2. As shown in Figure 3, the sensor assembly 200 may be rotatably 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 the leading rod axis 310, and the trailing connecting rod extends along the trailing rod axis 315. The leading rod axis 310 and the trailing rod axis 315 extend substantially parallel to the horizontal axis 320 of the sensor assembly 200. However, it will be understood that the angle of the axis 310 may vary with respect to the sensor assembly because the openings at the leading ends of the sensor assembly components are elliptical / elongated to allow the belt to change direction.

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

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

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

[0039] Figure 4 is a schematic perspective view of the electronic 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. In addition, the housing 210 includes a first portion 410 configured to receive a load cell and a second portion 415 configured to receive an electronic pod.

[0040] Figure 5 is a second schematic perspective view of the electronic equipment housing shown in Figure 4. As shown in Figure 5, the housing 210 includes a through-hole 500 configured to accommodate wiring between the load cell and the electronic equipment pod. In addition, a first portion 410 of the housing 210 includes a first guide rod opening 505 and a first driven rod opening 510. Furthermore, a second portion 415 of the housing 210 includes a second guide rod opening 515 and a second driven rod opening 520. These four openings are configured to receive connecting rods (see Figure 3). As shown in Figure 5, the first guide rod opening 505 and the second guide rod opening 515 may be elliptical / elongated so that the belt can be a turn-curve belt.

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

[0042] Figure 7 is a schematic perspective view of the electronics pod of the built-in sensor assembly shown in Figure 2. As shown in Figure 7, the 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. In addition, the electronics pod 235 includes at least one power source, such as a battery or a capacitor. As shown in Figure 7, the electronics pod 235 includes a first capacitor 705 and a second capacitor 710.

[0043] Capacitors are more advantageous than batteries for several reasons. Firstly, capacitors can charge faster than batteries. Because the sensor assembly passes the receiving module quickly, the time for electromagnetic induction charging is limited. Therefore, capacitors maximize the amount of charge that can be achieved in that short period. Secondly, capacitors discharge less than batteries at low temperatures. Since the disclosed conveyor can be used 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. Here again, since the disclosed belt system can be used in high-temperature environments, capacitors have an advantage over batteries.

[0044] Figure 8 is a schematic exploded view of the link and load cell assembly of the built-in sensor assembly shown in Figure 2. As shown in Figure 8, the link 205 may be substantially U-shaped and includes a first leg 800, a second leg 805, and a connecting portion 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 driven 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 Figure 10) and a second driven rod opening 825.

[0045] As further shown in Figure 8, the link 205 includes a lateral extension 830 having a cavity or receiving portion 835 configured to receive at least a portion of the load cell 215. In addition, the lateral extension 830 includes a threading opening 840 configured to receive a fastener 220 (through a fastening opening 845 of the load cell 215) and secure the load cell 215 to the link 205.

[0046] Figure 9 is another schematic exploded view of the link and load cell assembly. As shown in Figure 9, the link 205 is substantially U-shaped. Furthermore, as shown in Figure 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 accommodate a connecting rod. In addition, Figure 10 also shows the second guide rod opening 1005 described above. As illustrated, the second guide rod opening 1005 may be elliptical / elongated so that the belt can be a turn-curve belt.

[0048] Figure 11 is a second schematic diagram of the link. 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 schematic diagram of the third link. In Figure 12, the recess 1000 and the first driven rod opening 820 and receiving portion 835 are more clearly visible. As shown in Figure 12, a portion of the first driven rod opening 820 and the receiving portion 835 may intersect.

[0050] Figure 13 is a fourth schematic diagram of the link. Here again, the U-shaped configuration of link 205 is illustrated. In addition, as shown in Figure 13, the lateral extension may be shorter than the overall length of link 205. As illustrated, the overall length 1300 of link 205 extends between the leading end 1305 and the trailing end 1310 of link 205. The length 1315 of the lateral extension 830 is considerably shorter than the overall length 1300. This arrangement prevents the guide connecting rod from passing through the load cell. This provides 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 the load cell of the sensor assembly shown in Figure 2. The load cell 215 may include the fastener opening 845 discussed earlier at its tip and the rod opening 1400 at its rear end. (See also Figures 8 and 9.) Figure 15 is another schematic diagram of the load cell. Figure 15 shows the through-hole 900 passing through the load cell 215 more clearly.

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

[0054] In addition, pod 1600 includes a gyro sensor 1640 configured to detect the belt angle along three axes. For example, if the sensor assembly is detected to be oriented at a non-horizontal angle around the long axis (the front-to-back axis extending along the direction of belt movement), this may indicate that the belt is "bouncing," in which case a portion of the belt may be bouncing upward from its proper horizontal position. Similarly, pod 1600 includes an accelerometer 1645 configured to measure the belt acceleration along the same three axes. For example, detecting fluctuations in the belt acceleration along the long axis may indicate surging. Furthermore, by detecting the belt angle along the three axes and the belt acceleration along the three axes, six values ​​are provided that can be collectively analyzed to determine many other aspects of belt operation.

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

[0056] In addition, the pod 1600 may include an onboard controller 1605. The controller 1605 may include various computing and communication hardware, such as a server, circuit configuration, and display. Furthermore, the controller 1605 includes a device processor 1610 and a non-transitory computer-readable medium containing instructions executable by the device processor 1610 for performing the processing described herein, such as receiving and transmitting data. 1612 It includes and.

[0057] The internal components are configured to operate at relatively low voltages. This allows the system to continue operating even when the capacitor charge is low, maximizing capacitor utilization. In some embodiments, the internal controller is configured to function with a power supply in the range of approximately 0.1 to 5.5 volts. In some embodiments, the internal controller is configured to function with a power supply of less than approximately 5.5 volts.

[0058] A persistent 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 this Art). In some embodiments, a persistent computer-readable medium may include, for example, an electronic memory device, a magnetic memory device, an optical memory device, an electromagnetic memory device, a semiconductor memory device, or any suitable combination of such devices. More detailed examples of persistent computer-readable mediums 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 multipurpose disks (DVDs), memory sticks, and any suitable combination of these exemplary media. The persistent computer-readable mediums used herein should not be construed as transient signals such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through waveguides or other transmission media (e.g., light pulses passing through fiber optic cables), or electrical signals transmitted through wires.

[0059] Instructions stored on a persistent computer-readable medium to perform the operation of the present invention may include instruction set architecture (ISA) instructions, assembler instructions, machine instructions, machine-dependent instructions, microcode, firmware instructions, configuration data for integrated circuits, state-setting data, or source code or object code written in 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 this disclosure will be described in relation to diagrams showing flowcharts and / or block diagrams of methods, systems, and computer products. It will be understood that each block in the flowcharts and / or block diagrams is implemented by computer-readable instructions. The flowcharts and block diagrams in the diagrams show the configuration, functionality, and operation of possible embodiments of the various embodiments disclosed. Thus, each block in the flowchart or block diagram may represent a module, segment, or part of an instruction. In some embodiments, the functions described in the diagrams and claims may occur in an order other than that listed and / or illustrated.

[0061] The controller 1605 may include networking hardware configured to interface with other nodes in a network, such as a LAN, WLAN, or other network. Furthermore, 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 recognized that in some embodiments, the receiver and transmitter may be combined within the transceiver.) Any suitable communication platform and / or protocol may be used for communication between the controller 1605 and other components of the system. Since each of the various sources of information may have its own platform and / or protocol, the system may be configured to interact with each platform and / or protocol to receive data.

[0062] In some embodiments, the computer-readable medium of the controller 1605 1612 This includes instructions that can be executed by the processor 1610 to receive data from one or more sensors and to send the data to an external controller (offboard controller) 1700.

[0063] Figure 17 is a block diagram showing the external components of the data acquisition 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 persistent 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] You will notice that the receiver module may also include a device configured to electromagnetically inductively charge a power supply built into the belt as the belt passes over the receiver module. That is, the receiver module includes an electromagnetic induction charger configured to electromagnetically inductively charge a capacitor in an electronic pod built into the belt.

[0065] As shown in Figure 17, the 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 the customer and / or system manufacturer.

[0066] Alternatively, or in addition, an 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 a major failure.

[0067] Alternatively, or in addition, the external controller 1700 may be configured to trigger one or more warnings or alarms (1755) if the measured parameters fall outside a predetermined range. For example, if it is detected that the belt tension is above a predetermined threshold, a warning may be issued to allow the system to be checked. Similarly, a warning may be issued if the belt angle and / or belt acceleration fall outside a predetermined range.

[0068] Because driving data is collected alongside positional data, thresholds may be dynamic rather than static. For example, due to the nature of helical systems, belt tension typically increases as the belt ascends the helix. Therefore, thresholds may be dynamic, requiring lower tension to trigger an alert near the bottom of the helix and higher tension to trigger an alert near the top. For similar reasons, the acceptable range of belt acceleration may also be dynamic, as the belt is expected to accelerate at different amounts and in different directions at different points along its path. In addition, with respect to belt angle, the expected angle of the belt changes around its path because it moves not only horizontally but also vertically and along slopes (within the helix), and in some cases even over curves (e.g., around corners). Therefore, dynamic expectation of what the angle should be is used when considering the tolerance of the measured belt angle.

[0069] Furthermore, by collecting data on the belt path and recording the location 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 with a previously stored fingerprint.

[0070] Figure 18 is a flowchart illustrating a method for monitoring belt tension. It will be understood that the order of operations considered may vary somewhat. As shown in Figure 18, position data is collected in step 1800, while belt tension is detected in step 1805. 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 entire data collection. 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] In step 1820, a dynamic tension threshold is selected, and in step 1825, the measured tension is evaluated based on the collected position data to determine whether it exceeds the threshold at the corresponding position. If yes, an alarm is issued in step 1830, and the system continues to monitor the belt tension. If no, the system simply continues to monitor the belt's operation.

[0072] Figure 19 is a flowchart illustrating how the belt angle is monitored. Similar to Figure 18 above, position data is collected in step 1900, while the belt angle is detected in step 1905. Subsequently, the position data is downloaded / transmitted externally in step 1910, and the angle data is downloaded / transmitted externally in step 1915. A dynamic angle threshold (i.e., an acceptable range of angle values) is determined in step 1920 based on the position data, and an evaluation is performed in step 1925 to determine whether the detected angle falls within the acceptable range. It will be understood that this evaluation is performed for all three axes. If the belt angle falls outside the expected range for any of the three axes, a warning is issued in step 1930.

[0073] Figure 20 is a flowchart illustrating how belt acceleration is monitored. Position data is collected in step 2000, while belt acceleration is detected in step 2005. Subsequently, the position data is 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 performed in step 2025 to determine whether the detected acceleration falls within the acceptable range. It will be understood that this evaluation is performed for all three axes. If the belt acceleration falls outside the expected range along any of the three axes, a warning is issued in step 2030.

[0074] The embodiments discussed herein may be used in artificial intelligence to improve the efficiency and effectiveness of the disclosed systems. As used herein, “artificial intelligence” may include any methods known in machine learning and related fields. For example, artificial intelligence may include systems and methods used in deep learning and machine vision.

[0075] While various embodiments have been described, this description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more embodiments and configurations are possible within the scope of these embodiments. Many possible combinations of features are shown in the accompanying drawings and discussed in this detailed description, but many other combinations of the disclosed features are also possible. Unless specifically restricted, any feature of any embodiment may be used in combination with or as a substitute for 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. Accordingly, these embodiments are limited only in light of the appended claims and their equivalents. Furthermore, various modifications and changes can be made within the scope of the appended claims.

Claims

1. A sensor assembly for a conveyor belt, One or more sensors configured to be integrated with the conveyor belt and to collect data on the operating conditions of the belt, The device comprises a device processor and an internal controller including a non-temporary computer-readable medium, The computer-readable medium stores instructions executable by a processor in order to perform the functions of receiving data from one or more sensors and transmitting said data to an external controller. The aforementioned data regarding the belt operation status includes belt angle data. Sensor assembly.

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

3. The sensor assembly according to claim 1, wherein the computer-readable medium further includes an instruction to store the data relating to the belt operating conditions in a buffer before transmitting the data relating to the belt operating conditions to the external controller.

4. The sensor assembly according to claim 1, wherein the built-in controller is configured to function with a power supply of less than approximately 5.5 volts.

5. The sensor assembly according to claim 1, wherein the data relating to the belt operating status includes belt angle data for three different axes.

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

7. The sensor assembly according to claim 6, wherein the data relating to the belt operation status includes belt acceleration data along three different axes.

8. The sensor assembly according to claim 6, wherein the built-in controller is configured to function with a power supply of less than approximately 5.5 volts.

9. The sensor assembly according to claim 8, wherein the built-in controller is configured to function with a power supply in the range of approximately 0.1 to less than approximately 5.5 volts.

10. The sensor assembly according to any one of claims 1 to 9, wherein the belt angle data includes data relating to the attitude angle of the conveyor belt around at least one axis of three different axes.

11. A receiver module for a conveyor belt data acquisition system, A housing is provided which is located outside the belt and is positioned near the conveyor belt, The system comprises a device processor and a belt interface unit including an external controller having a non-temporary computer-readable medium that stores instructions executable by the device processor, The aforementioned command implements the function of receiving data regarding the belt operation status transmitted by a built-in controller integrated with the belt. The data relating to the belt operation status includes belt angle data, and is contained in the receiver module.

12. The receiver module according to claim 10, further comprising a device configured to electromagnetically induce charging of a power supply built into the belt as the belt passes through the receiver module.

13. The receiver module according to claim 10, wherein the data relating to the belt operation status includes belt tension data.

14. The receiver module according to claim 10, wherein the data relating to the belt operation status includes belt acceleration data.

15. The receiver module according to claim 14, wherein the data relating to the belt operation status includes belt acceleration data along three different axes.

16. The receiver module according to any one of claims 11 to 15, wherein the belt angle data includes data relating to the attitude angle of the conveyor belt around at least one axis of three different axes.

17. A conveyor belt operation monitoring system, One or more sensors, configured to be integrated with the belt and to collect data on the belt's operating status, The system comprises a first device processor and an internal controller including a first non-temporary computer-readable medium that stores instructions executable by the processor, The command receives data from one or more sensors, and This implements the function of transmitting the aforementioned data to an external controller. The conveyor belt operation monitoring system further includes at least one receiving module having a belt interface unit, the belt interface unit including a second device processor and an external controller including a second non-temporary computer-readable medium, the instruction fulfills the function of receiving the data transmitted by the internal controller, Two or more receiving modules are provided around the path of the belt, The system includes a mesh network of the two or more receiving modules.

Images