Preventive monitoring system for conveyor belts, and monitoring equipment

Abstract

The present invention generally pertains to the technological sector of industrial conveyor belts, and more specifically relates to a system for monitoring anomalies in industrial conveyor belt bearings, and equipment capable of monitoring the temperature of each bearing present in the rollers of industrial conveyor belts in real time, in order to detect abnormal temperature increases. The equipment (1) in question is a modular assembly comprising a MultiSensorG network cable, temperature sensors, a data module, and industrial communication networks. The system consists of the following steps: insertion of references (R), individual sensor readings, storage of data (D), comparative analysis, actuation, and replacement, when required.

Description

[0001] PREVENTIVE MONITORING SYSTEM FOR CONVEYOR BELTS AND MONITORING EQUIPMENT

[0002] FIELD OF INVENTION

[0003]

[0001] In general, the present invention belongs to the technological sector of industrial conveyor belts and refers, more specifically, to a system for monitoring anomalies in conveyor belt bearings and equipment capable of monitoring the temperature of each bearing present in the rollers of industrial conveyor belts in real time, in order to determine abnormal temperature elevations.

[0004] BACKGROUND OF THE INVENTION

[0005]

[0002] Bearings used in industrial conveyor belts generally do not suffer instantaneous breakage or irreversible damage, but rather a slow and gradual process that begins with undesirable excessive stress. Such stresses ultimately generate local heating, which leads to the expansion of the metal components of the bearings, reducing the movement space of the balls, increasing friction within the components, which ultimately causes temperature rise.

[0006]

[0003] This process is continuous, progressive and highly damaging to the industry, since, if not detected in time, it will result in the malfunction of the entire conveyor belt until its total loss.

[0007]

[0004] Conveyor belts can also become misaligned, causing the belt to deviate from its original position, resulting in unwanted dumping of products transported along the belt, causing high losses in most cases and leading to unscheduled stops in the operation until the problem is resolved.

[0005] There is also the possibility of a problem with clogging in the flow of products at the dumping points, since belt malfunction can prevent the products from being released at the scheduled locations.

[0008]

[0006] Another serious problem caused by the malfunction of industrial conveyor belts is the risk of work accidents involving conveyor belt operators, who are exposed to risks ranging from being hit by stuffed products, detached metal parts, to burns and other damages.

[0009]

[0007] That said, as an example of the problems highlighted above, it is possible to cite document CN213567973 (China Railway. 2020) which describes a belt conveyor roller operation detection device, comprising a position adjustment mechanism placed on the support of the belt conveyor roller support and a detection mechanism placed below the belt conveyor roller and installed on the position adjustment mechanism; the position adjustment mechanism comprises a fixed detection support and an adjustment component set below the fixed detection support and used to adjust the position of the detection mechanism; the detection mechanism comprises a generator set in the adjustment assembly, a friction wheel firmly attached to the belt conveyor roller and connected to the generator, and a detection indicator light placed on the adjustment assembly and connected to the generator.Using the detection mechanism, maintenance personnel can quickly judge whether the conveyor idler roller is faulty, improve work efficiency, reduce labor intensity, and have a simple structure and low cost.

[0008] However, the above-mentioned solution is only intended to resolve belt deviations and does not address the cause of the deviation, i.e., bearing damage, and thus incurs precisely the technical problems described above.

[0010]

[0009] There is also document US10690568 (Yokogawa. 2016) which discloses a system that calculates a temperature difference between corresponding spatial resolution zones based on a first temperature distribution obtained by a return light from a first optical fiber portion and a second temperature distribution obtained by a return light from a second optical fiber portion. The system calculates a temperature difference for evaluation for each spatial resolution zone, the temperature difference for evaluation being a sum of a temperature difference from each spatial resolution zone and a temperature difference from an adjacent spatial resolution zone.

[0011]

[0010] In a similar way to the first prior art, this invention does not act on the cause of the technical problems resulting from bearing wear, and thus, incurs exactly the technical problems previously described.

[0012]

[0011] Therefore, based on all the drawbacks existing in the systems and equipment currently used, described above in the state of the art, it is clear that there is a gap in the creation of a system for monitoring anomalies in industrial conveyor belt bearings and equipment capable of monitoring the temperature of each bearing present in the rollers of industrial conveyor belts in real time, in order to determine abnormal temperature increases.

[0013] SUMMARY AND OBJECTIVES OF THE INVENTION

[0012] In order to avoid the technical problems previously described, that is, the risk of unforeseen deterioration of the bearings, the invention proposed herein is equipped with temperature monitoring sensors, individually, for each roller bearing, all in real time, informing precisely where and if there is an excessive and unwanted heating process in any of these bearings.

[0014]

[0013] The system and equipment presented here can detect the temperature variation trend of each bearing and, simultaneously, allow one or more control temperatures to be assigned to each bearing, independently, and the equipment will perform the normality analysis based on these parameters.

[0015]

[0014] In this sense, it will be possible to obtain a normal reference temperature (TN) below which operation is considered normal. However, if the bearing exceeds this temperature, a warning will be immediately generated and the system will indicate which bearing is possibly having problems, before it is necessary to stop the conveyor belt.

[0016]

[0015] There will also be a risk temperature (TR) informed, from which the conveyor will be immediately and automatically switched off, in order to protect the equipment and the transported product, in order to avoid more severe industrial losses and damages, such as work accidents.

[0017]

[0016] Thus, the system and equipment proposed herein have a microprocessor system that receives all data measured by the sensors, stores them in a database and performs individual analysis of each sensor in real time using algorithms defined for this function, in order to ensure safe operation.

[0017] In order to remedy the flaws in the current state of the art highlighted above, the present invention patent aims to propose a solution for industrial conveyor belts, being capable of monitoring the temperature of each bearing present in the rollers of industrial conveyor belts in real time, in order to determine abnormal temperature elevations.

[0018] BRIEF DESCRIPTION OF THE FIGURES

[0019]

[0018] In order for the present invention to be fully understood and put into practice by any technician in this technological sector, it will be described in a clear, concise and sufficient manner, based on the attached drawings, which illustrate and support it, listed below:

[0019] Figure 1 represents the treadmill with the monitoring equipment installed.

[0020]

[0020] Figure 2 represents, by way of example, a single-line diagram of the installation of monitoring equipment on an industrial conveyor belt.

[0021]

[0021] Figure 3 represents the perspective view of the treadmill with the monitoring equipment installed.

[0022]

[0022] Figure 4 represents a detailed view of the distribution panel and the sensors applied to the rollers.

[0023]

[0023] Figure 5 shows the details of the front portion of the conveyor belt with the equipment applied.

[0024]

[0024] Figure 6 shows the details of the rear portion of the conveyor belt with the equipment applied.

[0025]

[0025] Figure 7 represents an exemplary flowchart of the system.

[0026] DETAILED DESCRIPTION OF THE INVENTION

[0027]

[0026] In order for the system and equipment described herein to be put into practice by any technician with reasonable knowledge of the subject, the monitoring equipment (1) has a microprocessor (not shown) that receives the data (D) measured by the bearing, motor and bearing temperature sensors (1.1), misalignment sensor (1.2) and speed sensor (1.3), or any other sensor that may be necessary, according to the project, and stores them in a pre-programmed database to compare said data (D) with the references (R) of normal temperature (TN) and risk temperature (TR), analyzing each sensor in real time and individually.

[0028]

[0027] It is worth noting that, preferably, the equipment will be programmed so that any sensor (1.1)(1.2)(1.3) that exhibits abnormal behavior or loss of signal will be immediately reported by the system itself, through the use of Ethernet IP networks, Profinet, DeviceNet, or any other equivalent means.

[0029]

[0028] The equipment (1) in question is a modular set composed of: a) MultiSensorG network cable (1.4), responsible for interconnecting all sensors to the distribution panel (2); b) Temperature sensors (1.1), preferably digital and addressable with Sheriff Module; c) MultiDataG Data Module arranged next to the panel (2), which stores all data and analyzes it, communicating with the fault information systems and automation system; d) Industrial communication networks, which will connect the Sheriff modules with the MultiDataG module and the automation system and / or main server and fault information boards.

[0030]

[0029] Misalignment sensors (1.2) are installed at various points along the belt and continuously monitor the belt position, detecting any deviation from its normal path. If the misalignment exceeds a predetermined limit, the system can automatically shut down the conveyor, preventing equipment damage and product loss.

[0031]

[0030] Clogging monitoring sensors are installed at the discharge ends of conveyors to detect any flow obstructions downstream of the installation, ensuring that the conveyor continues to operate under unsuitable conditions.

[0032]

[0031] The equipment includes safety systems, such as guard cables, which can be easily activated by personnel working near the conveyor. This allows workers to quickly stop the equipment in an emergency, ensuring their safety.

[0033]

[0032] By incorporating these capabilities into a single system, a comprehensive solution is achieved for monitoring and managing the common risks and issues faced by shippers at ports and grain facilities.

[0034]

[0033] By adopting this technology, companies can improve the safety and efficiency of operations, protecting their assets and workers and minimizing disruptions and losses associated with equipment failure.

[0035]

[0034] The system described herein has, in a preferred execution mode, a "Cloud Computing" service, which allows integration with a central online operating system, in order to guarantee remote monitoring, and is composed of the following steps:

[0036] I) Insertion of references (R) for normal temperature (TN) and risk temperature (TR);

[0037] II) Individual reading of each of the sensors on the conveyor belt (E) in operation;

[0038] III) Data storage (D) in a database;

[0039] I. Customization of control parameters;

[0040] IV) Comparative analysis of data (D) individually with the references; i. No action when the temperature is below TN; ii. Alert action when the measured temperature is higher than TN and lower than TR (TN <D<TR); ou iii. Atuação de desligamento da esteira (E) quando a temperatura medida está maior que TR (D> TR);

[0041] V) Replacement of the defective roller (3), if necessary.

[0035] The massive reading step of all bearings and risk points on a conveyor is of vital importance to measure the temperature in each existing bearing, as they all have the same level of importance when it comes to the potential to cause damage and risks.

[0036] Early detection of problems allows monitoring the temperature variation trend of each bearing, the system can identify local heating and potential problems before they become critical.

[0037] Customization of control parameters allows assigning specific control temperatures to each bearing, facilitating the analysis of normality and the detection of deviations.

[0042]

[0038] Alarms and indications allow you to indicate when a bearing exceeds the normal temperature (TN), an alarm is triggered, alerting operators to the problem and indicating which bearing needs to be inspected.

[0043]

[0039] Automated protection allows you to indicate if a bearing reaches the risk temperature (TR), the system will automatically shut down the conveyor, protecting the equipment, the transported product and the workers in the area.

[0044]

[0040] Reducing downtime allows problems to be detected early and acted upon quickly and efficiently. The system can help avoid long periods of downtime, keeping operations running and minimizing financial and productivity losses.

[0045]

[0041] The system, in addition to monitoring bearing temperatures, also addresses other common conveyor issues, such as track misalignment and personnel safety. These additional features are important to ensure efficient and safe operations.

[0046]

[0042] In a second construction modality, the equipment can be applied without the network cable (1.4) in order to interconnect all the sensors to the distribution panel (2) via Bluetooth or wireless signal.

Claims

CLAIMS:

1. PREVENTIVE MONITORING EQUIPMENT FOR CONVEYOR BELTS which comprises a microprocessor (not shown), MultiSensorG network cable, temperature sensors, MultiDataG data module and communication networks characterized by the sensors (1.1)(1.2)(1.3) being interconnected via MultiSensorG network cable to the distribution panel (2), the sensors (1.1)(1.2)(1.3) being preferably digital and addressable with Sheriff Module and by the MultiDataG data module storing and comparatively analyzing the data in communication with the fault information systems and automation system.

2. PREVENTIVE MONITORING EQUIPMENT FOR CONVEYOR BELTS, according to claim 1, in a second construction modality characterized in that the equipment interconnects the sensors (1.1)(1.2)(1.3) with the panel (2) via signal without the use of a cable.

3. PREVENTIVE MONITORING SYSTEM FOR CONVEYOR BELTS, using the equipment of claim 1, characterized by having the following steps: I) insertion of references (R); II) individual reading of sensors (1 .1 )(1 .2)(1 .3); III) data storage (D); IV) comparative analysis; V) performance and replacement, if necessary.

4. PREVENTIVE MONITORING SYSTEM FOR CONVEYOR BELTS, according to claim 2, and further characterized by stage IV presenting the following substages: i. Remain without action, when the temperature is below TN; ii. Perform Alert action, when the measured temperature is higher than TN and lower than TR (TN <D<TR); ou iii. Efetuar atuação de desligamento, quando a temperatura medida está maior que TR (D> TR).

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