Device, system and method for detecting damage to a conveyor belt

Abstract

A device (12) for a conveyor belt (11) to detect damage to the conveyor belt (11), the device (12) including a transponder (14) and a wire arrangement (23) extending from the transponder (14), wherein the transponder (14) is configured to provide a data signal including: a state of the wire arrangement (23) being in one of a broken state and an unbroken state and; a transponder identifier. Systems (10, 31) including the device (12) and one or more readers (15) to receive data from the device (12) and related methods of use and installation are also disclosed.

Description

Device, System and Method for Detecting Damage to a Conveyor BeltRelated Applications

[0001] This application claims priority from Australian provisional patent application no. 2024902373 filed on 31 July 2024, the contents of which are incorporated by reference.Technical Field

[0002] The invention relates to a device, system and method for detecting damage to a conveyor belt. In particular, the invention relates to a device, system and method for detecting and locating damage to a conveyor belt such as a rip or a tear in a conveyor belt used in materials transportation such as the conveying of crushed material.Background

[0003] Conveyor belts may be embedded with various forms of conductor loops which extend across the width of the conveyor belt. The conductor loops provide a closed loop current path usually formed of a conducting material such as copper or steel wire. These conductors remain substantially de-energised, i.e. no current flow, until they pass a detector, such as a coil, which induces a current flow within the conductor.

[0004] A remote detection means is then used to monitor or detect the inducted current flow in the conductor loop. This information can be used to detect the occurrence of a rip or tear in the belt. For example, if a belt tears and breaks the conductor loop, then this can be detected.

[0005] A problem with such conductor loops is that they are susceptible to damage such the loop being broken by repeat passage through rollers. Another problem relates to cost to replace and repair such conductor loops. Yet another problem relates to the conductor loop or arrangement of conductor loops not providing an indication of the size or location of belt tears.

[0006] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.Summary

[0007] In accordance with a first broad aspect there is provided, a device for fitting within a conveyor belt to detect damage to the conveyor belt, the device including a transponder and a wire arrangement extending from the transponder, wherein the transponder is configured to provide a data signal including: a state of the wire arrangement being in one of a broken state and an unbroken state and; a transponder identifier.

[0008] In an aspect, the wire arrangement is an elongate wire loop arranged to extend from the transponder.

[0009] In another aspect, the wire loop is twisted.

[0010] In yet another aspect, the terminal ends of the wire loop are in electrical communication with the transponder.

[0011] In yet another aspect, the terminal ends of the wire loop are in direct electrical connection with the transponder.

[0012] In yet another aspect, a length of the wire loop between its terminal ends and its free end is at least about 1 metre.

[0013] In yet another aspect, the wire loop is a wire coated by an insulating cover.

[0014] In yet another aspect, the device and the wire loop and its termination to the device are completely encased by a covering.

[0015] In yet another aspect, the covering includes rubber arranged to encase the wire loop and the transponder therebetween.

[0016] In yet another aspect, the transponder includes a dipole antenna.

[0017] In yet another aspect, the wire arrangement and dipole antenna are generally linearly arranged.

[0018] In yet another aspect, the transponder includes a RFID device (Radio Frequency Identification) device>

[0019] In yet another aspect, the RFID device is a passive RFID device excitable by an associated reader.

[0020] In accordance with a second main aspect there is provided, a device fittable to a conveyor belt to detect damage to the conveyor belt, the device including an RFID (Radio Frequency Identification) device with a dipole antenna, and an elongated wire arrangement including a twisted wire loop extending from the RFID device with its terminal ends coupled to a chip of the RFID device, the twisted wire loop and the dipole antenna being generally linearly arranged such that the device has a slender profile, wherein the RFID device is configured to provide data signal indicating: a state of the wire arrangement being in one of a broken state and an unbroken state and; a transponders unique identification number, when the transponder passes an associated reader thereby enabling detection of damage to the belt.

[0021] In accordance with a third main aspect there is provided, a conveyor belt fitted with one or devices as defined above and herein, the devices being located at spaced apart intervals across the conveyor belt.

[0022] In accordance with a fourth main aspect there is provided, a conveyor belt rip detection system, the system including a plurality of devices as defined above and herein, the plurality of devices being arrangeable at spaced apart intervals along thelength of the conveyor belt and one or more readers adapted to excite and read data from the plurality of devices.

[0023] In accordance with a fifth main aspect there is provided, a conveyor belt damage detection system including: a conveyer belt adapted with slots or formed grooves on an underside thereof at spaced apart intervals across a conveyor belt, and plurality of devices fitted to each of the slots, and a reader adapted to excite and read data from the plurality of devices, wherein each of the devices includes a transponder and a wire arrangement extending from the transponder, the transponder is configured to provide data signal indicating: a state of the wire arrangement being in one of a broken state and an unbroken state and; a transponder identifier, when the transponder passes the reader thereby enabling detection of damage to the conveyer belt.

[0024] In an aspect, the wire arrangement is an elongated wire loop arranged to extend from the transponder.

[0025] In another aspect, the wire loop is twisted.

[0026] In yet another aspect, the terminal ends of the wire loop are in electrical communication with the transponder.

[0027] In yet another aspect, the terminal ends of the wire loop are direct electrical connection with the transponder.

[0028] In yet another aspect, a length of the wire loop between its terminal ends and its free end is at least about 1 metre.

[0029] In yet another aspect, the transponder includes a dipole antenna.

[0030] In yet another aspect, the wire arrangement and dipole antenna are generally linearly arranged within the respective slots of the belt.

[0031] In yet another aspect, the transponder includes an RFID (Radio Frequency Identification) device.

[0032] In yet another aspect, wherein the RFID device is a passive RFID device.

[0033] In accordance with a sixth main aspect there is provided, a method of detecting damage to a conveyor belt, the method including: receiving a signal from one or more devices including a transponder and a wire arrangement locating within the belt, the signal including data indicative of identity of each of the one or more devices and a state of the wire arrangement being in one of a broken state and an unbroken state.

[0034] In an aspect, the transponder is a passive RFID device and the method includes exciting the passive RFID device with an RFID device reader, and then reading the data provided by the passive RFID device.

[0035] In accordance with a seventh main aspect there is provided A method of fitting devices to a conveyor belt to detect damage of the conveyor belt, the method including: Forming spaced apart elongate slots at an underside of the conveyor belt between opposing edges of the conveyor belt; and, Locating respective devices into the slots with an elongate wire extending from a transponder of each of the devices substantially along the respective slots; and Affixing the devices to the respective slots.

[0036] In an aspect, the elongate slots are formed with a cutting tool.

[0037] In yet another aspect, the method includes covering the devices with rubber.

[0038] In yet another aspect, the method includes covering the device in a rubber casing prior to it being locating within the elongate slots.

[0039] In yet another aspect, the step of affixing the devices to the slots includes bonding the rubber to the respective elongate slots.Brief Description of the Figures

[0040] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which;

[0041] Figure l is a side view illustrating a conveyor belt rip detection system showing the example locations of devices fitted to the belt;

[0042] Figure 2 is a top view illustrating a conveyor belt rip detection system showing the example locations of the devices;

[0043] Figure 3 is another top view illustrating a conveyor belt rip detection system illustrating an alternative configuration of the devices;

[0044] Figure 4 is a block diagram illustrating the conveyor belt rip detection system including one or more devices;

[0045] Figure 5 is a perspective view illustrating a preferred example of the device;

[0046] Figure 6 is a is a perspective view illustrating the preferred example of the device fitted within a cover;

[0047] Figure 7a is a side view illustrating an internal configuration of a belt with the device fitted relative to an internal wire of the belt;

[0048] Figure 7b is a side sectional view illustrating the preferred example of the device fitted to the belt relative to internal wires of the belt; and,

[0049] Figure 8 is a top view illustrating the belt with surfaces removed to reveal the internal configuration of the devices within the belt.Detailed Description

[0050] Referring to Figures 1 to 4 there is shown a conveyor belt rip detection system10 for detecting damage such as rip or tear in a conveyer belt 11. The system 10 includes a plurality of detection devices 12 that are located within the belt 11 at spaced apart intervals and at least one reader 15 adapted to communicate with the plurality of detection devices 12.

[0051] The plurality of devices 12 each include a communication means 13 that may be or include a transponder 14 adapted to communicate with the reader 15 and a breakable body 16 that is adapted to break in response to the belt 11 being damaged such as being ripped or tom. The communication means 13 may be provided at a head 18 of the device 12 and the breakable body 16 may be provided as an elongate stem or tail 20 of the device 12.

[0052] In the examples provided herein, the transponder 14 is or includes an RFID (Radio Frequency Identification) device 22, commonly known as an RFID device Tag, and the breakable body 16 may be a wire arrangement 23 that may be a wire loop 24 that is twisted to an elongate form to provide the stem or tail 20 extending form the RFID device 22. An example of the wire loop 24 is best shown in Figure 5 and is further detailed below. It is noted that whilst an RFID device type transponders are preferred in this example, other forms of transponders may be used, and such examples are contemplated herein.

[0053] The detection devices 12 may be adapted to embed in the conveyor belt 11 at spaced apart locations within body 30 of the belt 11 with the RFID device 22 generally located toward a first side 26 of the belt 11 and the wire loop 24 extending toward a second opposing side 28 of the belt 11. Any suitable spacing, arrangements or widths may be used. However, generally, the wire loop 24 may span a width “W” of the belt11 which may be about 1 metres to 2 metres. However, it is noted the wire loop 24 may in some examples have a length anywhere from 0.4 metres to 6 metres.

[0054] However, this example, the length may be about 1.8 metres which about the width of the conveyer belt 11 as used in materials handling. However, other orientations may be used such as, but not limited to, angled and lengthwise orientations relative tothe belt 11. The device 12 have the same orientation as shown in Figure 2 or may be alternating as shown in Figure 3.

[0055] The reader 15 is adapted to detect a signal associated with each of the plurality of RFIDs 22 upon respective ones of the devices 12 passing the at least one reader 15. In this example, the RFID device 22 is preferably a passive RFID device and it is activated when it passes the reader 15 to provide the signal. The reader 15 thus needs to emit a radio frequency signal sufficient to energise and active the RFID device 22.

[0056] In more detail, as best shown in Figures 4 and 5, the RFID devices 22 include a chip 32 and an antenna 34 may extend from one or both sides of the chip 32. Preferably, as best shown in Figure 5, the antenna 34 may be a dipole antenna 36 extending from opposing sides of the chip 32. The dipole antenna 36 may be configured such that the RFID device 22 may operate in radio frequency “RF” range that may be in the range of about, but not limited to, 840 - 960 MHz. It is noted the wire loop 24 and the antenna 34 are separate parts which perform separate functions.

[0057] The wire loop 24 may be a single continuous elongate wire that is connected at both its terminal ends 38 to the RFID device 22, more specifically, the terminal ends 38 connect to the chip 32 so as to be in electrical communication with the chip 32. Specifically, the terminal ends 38 are in direct electrical communication with the chip 32.

[0058] The wire loop 24 may be twisted to bring the loop together into a single elongate twisted wire arrangement 40 which has a free end 37 which is the end loop of the wire 24. The wire loop 24 may be an insulated silicone covered metal wire. However, other coated or flexible wires may also be used. The twisted wire loop 24 may be slender have a width less than about 10 millimetres and a length that may be greater than about 1 metre, and this having an aspect ratio of greater than about 100.

[0059] The chip 32 may be or be part of an integrated circuit board (not shown) and the chip 32 may be programmable such that when energised a signal indicate of the state of the wire loop 24 is provided to the reader 15. For example, a first signal type may beprovided when the circuit between the chip 32 and wire loop 24 is not broken and a second signal type may be provided when the circuit between the chip 32 and wire loop 24 is broken, indicating that the wire loop 24 is broken and thus the belt 11 may be damaged. Of course, if a device 12 is badly damaged it may return no signal.

[0060] As best shown in Figure 5, in this example, the RFID device 22 and its chip 32 may be a commercial Higgs™ 9 RFID device Tag Integrated Chip available from Alien™. The Antenna 34 is connected to circuit board 45 with pads 47 of this chip 32 and two additional pads 51, 53 are provided to directly electrically connect ends of the wire loop 24 to the chip 32. The chip 32 and the dipole antenna 36 may be covered with a sheath or wrapping 57.

[0061] At least one reader 15 may be configured to excite and read the signal associated with each of the plurality of devices 12 within a range of about 1 to 10 metres. The reader 15 may be placed above, below or alongside the belt 11, as required. At least one reader 15 includes a reader transmitter & antenna 46 arrangement configured to excite and read the return signal from the RFID devices 22 of the device 12. In some examples, a broad-spectrum signal or multiple frequencies may be required to excite the RFID devices 22, and some RFID devices 22 could be configured to operate at different frequencies. It is noted that frequency ranges may change for different country specified statutory requirements

[0062] When the RFID devices 22 are energised by the reader 15, the reader 15 receives two responses as written variables from the RFID devices 22 which are read by the reader 15. The responses or date received by the reader 15 are (1) the unique RFID device 22 identification number; and (2) the status of the connection of the two terminals of the chip 32 connected to the wire loop 34, which may either a 0 or 1 with 0 = the loop is intact, and 1 = the loop is broken. As such, the data received allows the specific RFID device 22 to be identified and also whether or not the wire 24 is in a broken or unbroken state.

[0063] The at least one reader 15 may include or be associated with a computer system 31 having a processor 33 with associated memory 35 configured to read the signal andprovide an alert if a damages event is detected. An example of such a computer system 31 may be a belt management system (not shown).

[0064] The signal may include an identifier associated with the RFID device 22 of a specific device 12 and a state signal indicating the state of the device 12, specifically the wire loop 24, being unbroken or broken. It is noted that preferably a plurality of readers 15 are provided along the path of travel of the belt 11 which allows data to be continuously read from the devices 12 to detect damage and the location of the damage to the belt 11.

[0065] The computer system 31 may store in its associated memory 35 predetermined threshold values for the signal characteristics for each plurality RFID devices 22 including at least its position, length and lifecycle information. Accordingly, the system 31 is able to perform a method to determine which and how many of the devices 12 are damaged and where on the belt 11 these devices 12 are located.

[0066] The computer system 31 may be configured to undertake a further method to compare the signal characteristics to the threshold values and raise the alert should the values fall outside the expected range. The computer system 31 may also be configured to undertake a method to provide information about the position and size of the damage event based on the signal received from the RFID devices 12.

[0067] For example, if several adjacent ones of the plurality of devices 12 are a broken at the same time, then this may trigger a significant damage event whereas if a single or two devices 12 are broken this may simply trigger a lower warning state. The devices 12 may be quite closely spaced such as that shown in Figure 8 which allows the location of any damages to be more accurately determined.

[0068] Referring to Figure 6, the device 12 may be fitted with a covering 42 so that the device 12 presents in a single elongate linear form to provide a detection unit 48. The covering 42 may be formed from two pieces of rubber 44a and 44b which may be secured together, such as by gluing, with the device 12 sandwiched therebetween. In other examples, the devices 12 may be covered or coated using a vulcanising process.

[0069] Referring to Figures 7a and 7b, the device 12 may be provided or formed with a belt 11 when it is originally manufactured or the device 12 may be retrofitted to an existing belt 11. When the device 12 is retrofitted to a belt 11, a fitting method may include forming elongate slots or grooves 49 along an underside 50 of the belt 11 and locating the device 12 along the slots 49. The slots or grooves 49 may be formed by a method using a tool (not shown) which cuts or digs out material of the body 30 of the belt 11.

[0070] The slots or grooves 49 may be formed in a direction across the belt 12 and have a depth short of the belt wires 52 which extend lengthwise along the belt 11. Preferably, the device 12 may be provided in the form of the covered detection unit 48 which is shaped to be received by and fit along the slot 49. The detection units 48 may be located proximate to and transverse the underside 50 of the belt 11 as shown in Figure 8.

[0071] Such slots or grooves 49 may be made at relatively close intervals such as 10 centimetres to 60 centimetres and preferable about centimetres 20 to 60 centimetres which allows the devices 12 to be quite closely spaced to provide good accuracy in relation to when and where the belt 11 is damaged.

[0072] Advantageously, there has been provided a belt rip detection device, system and methods for detecting and determining damage to a conveyor belt. The device, system and method may employ RFID device technology which may be relatively robust and inexpensive. Specifically, the device including an RFID device and an elongate twisted wire loop allow the device to be placed or embedded into new and existing belts, and the elongate twisted wire loop may extend within the belt.

[0073] Then, when the belt is damaged the elongate twisted wire loop may break and this is detectable when the RFID device passes the reader. The information obtainable by the reader may include the state of the device, broken or unbroken, and identification of the device which may be mapped to its location along the belt. Further, the system may track and detect when multiples of the devices are in a broken state and may be configured to provide alerts based on the detected operating condition of the belt.Further still, the device or covered unit may be easily retrofitted to a belt by forming slots and then fitting the devices or covered units into the slots therefore making a cost effective to add the device to a belt and also replaced devices that may need maintenance.

[0074] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0075] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0076] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

[0077] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims

The claims defining the Invention are as follows:

1. A device for fitting within a conveyor belt to detect damage to the conveyor belt, the device including a transponder and a wire arrangement extending from the transponder, wherein the transponder is configured to provide a data signal including: a state of the wire arrangement being in one of a broken state and an unbroken state, and; a transponder identifier.

2. The device according to claim 1, wherein the wire arrangement is an elongate wire loop arranged to extend from the transponder.

3. The device according to claim 2, wherein the wire loop is twisted.

4. The device according to claim 2 or claim 3, wherein terminal ends of the wire loop are in direct electrical connection with the transponder.

5. The device according to claim 4 wherein a length of the wire loop between its terminal ends and its free end is at least about 1 metre.

6. The device according to any one of claim 2 to 5 wherein the wire loop is a coated wire.

7. The device according to any one of claim 2 to 6, wherein the device and the wire loop are encased by a covering.

8. The device according to claim 7, wherein the covering includes rubber arranged to encase the wire loop and the transponder therebetween.

9. The device according to any one of the previous claims, wherein the transponder includes a dipole antenna.

10. The device according to claim 9, wherein the wire arrangement and dipole antenna are generally linearly arranged.

11. The device according to any one of the previous claims, wherein the transponder includes a RFID (Radio Frequency Identification Device) device.

12. The device according to claim 11, wherein the RFID device is a passive RFID device excitable by an associated reader.

13. A device fittable to a conveyor belt to detect damage to the conveyor belt, the device including an RFID (Radio Frequency Identification) device with a diploe antenna, and an elongate wire arrangement including a twisted wire loop extending from the RFID device with its terminal ends coupled to a chip of the RFID device, the twisted wire loop and the diploe antenna being generally linearly arranged such that the device has a slender profile, wherein the RFID device is configured to provide data signal indicating: a state of the wire arrangement being in one of a broken state and an unbroken state, and; a transponder identifier, when the transponder passes an associated reader thereby enabling detection of damage to the belt.

14. A conveyor belt fitted with one or devices as defined in any one of claim 1 to 13, the devices being located at spaced apart intervals across the conveyor belt.

15. A conveyor belt rip detection system, the system including a plurality of devices as defined in any one of claim 1 to 13, the plurality of devices being arrangeable at spaced apart intervals across a conveyor belt and one or more readers adapted to excite and read data from the plurality of devices.

16. A conveyor belt damage detection system including: a conveyer belt adapted with slots on an underside thereof at spaced apart intervals across a conveyor belt, and plurality of devices fitted to each of the slots, and a reader adapted to excite and read data from the plurality of devices, wherein each of the devices includes a transponder and a wire arrangement extending from the transponder, the transponder is configured to provide data signal indicating: a state of the wire arrangement being in one of a broken state and an unbroken state and; atransponder identifier, when the transponder passes the reader thereby enabling detection of damage to the conveyer belt.

17. The system according to claim 16, wherein the wire arrangement is an elongate wire loop arranged to extend from the transponder.

18. The system according to claim 17, wherein the wire loop is twisted.

19. The system according to claim 18, wherein terminal ends of the wire loop are in direct electrical connection with the transponder20. The system according to claim 19, wherein a length of the wire loop between its terminal ends and its free end is at least about 1 meter.

21. The system according to claim 16, wherein the transponder includes a dipole antenna.

22. The system according to claim 21, wherein the wire arrangement and the dipole antenna are generally linearly arranged within the respective slots of the belt.

23. The system according to any one of claims 16 to 22, wherein the transponder includes a RFID device (Radio Frequency Identification Device).

24. The system according to claim 23, wherein the RFID device is a passive RFID device.

25. A method of detecting damage to a conveyor belt, the method including: receiving a signal from one or more devices including a transponder and a wire arrangement locating within the belt, the signal including data indicative of identity of each of the one or more devices and a state of the wire arrangement being in one of a broken state and an unbroken state.

26. The method according to claim 25, wherein the transponder is a passive RFID device and the method include exciting the passive RFID device with a reader, and then reading the data provided by the passive RFID device.

27. A method of fitting devices to a conveyor belt to detect damage of the conveyor belt, the method including: a. Forming spaced apart elongate slots or grooves at an underside of the conveyor belt between opposing edges of the conveyor belt; and, b. Locating respective devices into the slots with an elongate wire extending from a transponder of each of the devices substantially along the respective slots; and c. Affixing the devices to the respective slots.

28. The method according to claim 27, wherein the elongate slots or grooves are formed with a cutting tool.

29. The method according to claim 27, wherein the method includes covering the devices with rubber.

30. The method according to claim 28, wherein the method includes covering the device in a rubber casing prior to it being locating within the elongate slots or grooves.

31. The method according to claim 29, wherein the step of affixing the devices to the slots includes bonding the rubber to the respective elongate slots or grooves.

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