Centring-idler station for a conveyor belt

Abstract

The invention relates to an autonomous centring-idler station located on a conveyor belt every two existing upper idlers, which solves the problem of existing robust aligning systems which, most of the time, do not fulfil their purpose. The station provides safety, helps to keep the conveyor belt centred and is a complement that helps control operational costs, in comparison with current self-aligning systems. The station comprises a frame-like structure that supports a roller or idler which exerts continuous friction against the left and right edges of the conveyor belt, the frame-like structure being disposed on the conveyor belt using the existing structures. The centring station enables the correct movement position of the conveyor belt to be maintained during the movement thereof, by means of the centring rollers or idlers, arranged opposite each other on the left and right sides of the belt, wherein each centring roller is disposed at a 45° angle, supported by a rolling shaft that is mounted on ball bearings, disposed at a 45° angle and supported between two metal plates. The rolling shaft is inserted inside a tube or cylindrical sleeve made of mild steel that allows the shaft to roll therein and also protects same, such that the HDPE centring idler rotates reliably, supported at the ends thereof on the ball bearings.

Description

[0001] A CENTERING PULLEY STATION FOR A CONVEYOR BELT.

[0002] Field of Invention

[0003] The present invention relates to systems for centering or aligning a conveyor belt, more particularly to a centering roller station for a mining conveyor belt.

[0004] Background of the Invention

[0005] The aspects of this invention are generally related to a station for centering or aligning a mining conveyor belt, so as to prevent its deviation with respect to its longitudinal axis, the Y-axis.

[0006] Like any type of machinery, conveyor belt systems will eventually experience problems, regardless of how well maintained the conveyor belt parts are. It is normal for problems to arise, especially considering that conveyor belts are one of the most widely used pieces of equipment in many industries.

[0007] While some problems are inevitable, there are ways to prevent the most common issues and extend the lifespan of conveyor belt components. Below are some of the most common conveyor belt problems and how to prevent them.

[0008] Material spill

[0009] It's inevitable that material will slip, roll, or spill accidentally, especially in operations that handle large quantities of heavy bulk material. However, if the conveyor belt system is experiencing an increase in spill incidents, it could be due to areas causing excessive shaking or rattling.

[0010] To prevent material spills, ensure your conveyor belt system is properly maintained. Clean the conveyor belt and its components regularly and consider installing impact beds. Seized rollers

[0011] Excessive material spillage is the most common cause of roller seizing, which can completely halt production. To prevent downtime, a high-humidity seal and an anti-blocking shield are typically installed.

[0012] Material lockout

[0013] Material blockages can occur due to wear on the conveyor belt, sharp edges, and weak points in the system. When jams occur, they can cause the conveyor belt to simply seize up.

[0014] Deviated conveyor belt

[0015] Belt swerve occurs when the conveyor belt shifts too far to one side, which can lead to spillage and blockages of material, as well as premature wear on other parts of the conveyor belt. The best way to prevent a conveyor belt from swerving is to perform regular inspections and adjustments. If you notice small signs of misalignment, such as uneven belt wear, address them immediately before they become larger problems.

[0016] In the state of the art there is a large number of patents related to systems to prevent deviation or misalignment of a conveyor belt.

[0017] There are certain disadvantages related to the systems on the market for preventing the deviation or misalignment of a conveyor belt, related to the limited capacity to withstand stresses and loads, resulting in failures in their structural design and the short lifespan of their components, which become unusable after a period of time, affected by the stresses to which the conveyor belts are subjected.

[0018] Limitations of Current Self-Aligning Systems

[0019] Misalignment Correction: Current systems are primarily designed to correct misalignments when operating parameters deviate from specifications. However, they are not focused on preventing these problems or identifying the underlying causes of the deviations.

[0020] Lack of Focus on Safety and Maintenance: Self-aligning systems don't always prioritize safety to prevent damage or early identification of deviations. Furthermore, they don't alert users to the need for maintenance to keep the belt in optimal condition throughout its lifespan.

[0021] Examples of such a system for correcting the deviation or misalignment of a conveyor belt are described, for instance, in Korean patent publication No. KR101231796B1, which relates to a deflection prevention device for a conveyor belt. This device eliminates deviations of the return belt while simplifying the configuration, thereby increasing the conveying capacity of raw materials, minimizing damage to the conveyor belt, and facilitating maintenance, in addition to improving the quality of the conveyor belt. The deflection prevention device for the conveyor belt is installed on the upper side of the conveyor frame so that the belt is held by the carrier roller to transport the raw material. The lower side of the conveyor frame is installed on the conveyor belt to prevent the return belt from deviating.

[0022] The deviation prevention device includes a deviation prevention bar that is freely coupled to the center of the lower bar of the conveyor belt frame via a bearing, and a pair of tapered rollers installed on both sides of the bar. It is characterized by including a stop to prevent endless rotation.

[0023] Another example can be found in the Dutch patent granted to CenTrax, relating to an alignment system for conveyor belts, comprising conical rollers, which immediately detects even the slightest misalignment. The central roller instantly guides the conveyor belt to the correct position.

[0024] The tapered rollers are mounted to rotate freely within a frame that is freely adjustable in width and height, making it easy to adapt to virtually any conveyor belt design. The robust yet extremely flexible rotary bearing ensures exceptionally fast left or right turn and is highly sensitive to any signs of conveyor belt misalignment.

[0025] Yet another example can be found in the U.S. patent granted to Martin Engineering for the Martin Tracker™, which provides continuous and immediate precision adjustment of errant conveyor belts. The Tracker™ operates where other belt alignment devices fail to reduce edge damage.

[0026] The strap stays aligned with automatic and continuous adjustments.

[0027] Improved tracking reduces edge damage, spills, and maintenance costs.

[0028] However, it has been discovered, in the case of the present description, that the large efforts or stresses involved during the transport of bulk material on a conveyor belt exert a great deal of pressure on all the mechanical parts of the rollers, frame and idlers, causing wear and potentially also an increase in the weakness of the material over time.

[0029] There remains a need for a less robust centering system that provides safety, helps keep a conveyor belt centered, and is a complement that allows for cost control of operations for current self-aligning systems.

[0030] A field test was conducted, successfully demonstrating the equipment's operability on a 120-meter-long conveyor belt that had been poorly designed by a supplier due to its lack of adequate flexibility. Specialized personnel were unable to correct the problem after 10 days of attempts. However, thanks to the installation of the centering roller station described herein, the belt remains operational, despite its natural tendency to become misaligned due to its original, unfavorable structural design.

[0031] Brief Description of the Invention

[0032] One object of the present description is to provide a new, sturdy, and not as robust as what is known in the art to keep a conveyor belt aligned, formed by a station of centering rollers and scaled design solutions according to the operating requirements and specifications of the conveyor belt and repair.

[0033] Four-Mode Scaled Design

[0034] First option:

[0035] Features: Basic self-aligning system with essential components.

[0036] Benefits: Reduced cost, easy installation and maintenance, immediate improvement in alignment.

[0037] Second option:

[0038] Features: Basic sensors for monitoring and manual voltage adjustments.

[0039] Benefits: Greater accuracy in alignment, monitoring of component wear.

[0040] Third modality:

[0041] Features: Advanced sensors and automatic stops

[0042] Benefits: Automatic alignment, significant reduction in downtime, maintenance alerts.

[0043] Fourth modality:

[0044] Features: Integration with centralized management and monitoring systems.

[0045] Benefits: integration with other plant systems such as the pull cord safety switch.

[0046] The object of the description is achieved through the aspects characterized by what is set forth in the independent claims. Some modalities of the description are described in the dependent claims.

[0047] The embodiments and features, if any, described herein, which are not within the scope of the independent claims, should be construed as useful examples for understanding various embodiments of the embodiment. Some aspects of the embodiment are defined by the independent claims. The embodiment is based on the idea of ​​providing a less robust and sturdy structure to support the system of centering rollers arranged at a 45° angle, which exert a continuous, regulated tension on the edge of the conveyor belt and prevent its misalignment.

[0048] One advantage of the description is that the structure to support the centering roller system is a complement to the current self-aligning systems and electronic safeguards, reducing operating costs, premature wear, corrective shutdowns and risks to the personnel involved due to bad practices.

[0049] Brief Description of the Figures

[0050] The description will then be described in greater detail by means of some modalities with reference to the accompanying figures, in which:

[0051] Figure 1 is a perspective view of a conveyor belt including the centering roller station, according to the present utility model.

[0052] Figure 2 is a front elevation view of a conveyor belt including the centering roller station, without the protective grates, according to the present utility model.

[0053] Figure 3 is an enlarged view of the centering roller station, according to the present utility model.

[0054] Figure 4 is a schematic perspective view of a standard belt cut-off switch to be used in the centering roller system corresponding to the left side, according to the present utility model.

[0055] Figure 5 is a schematic perspective view of a standard belt misalignment switch to be used in the centering roller system corresponding to the left side, according to the present utility model.

[0056] Figure 6 is a front and side elevation view of the centering roller, according to the present utility model.

[0057] Figure 7 is an anterior and lateral elevation view of the rolling axle and the tube or sleeve surrounding such axle, according to the present utility model.

[0058] Figures 8 to 11 are elevation views of the detail of the joining of the centering rollers, according to the requirements of the user and belt depending on its use and location, according to the present utility model.

[0059] Description of Preferred Options

[0060] In Figure 1, a perspective view of the autonomous centering roller station (1) located on a conveyor belt (2) every two existing upper rollers (P) can be observed, with removable protective grilles (R) for the safety of the operating personnel, the centering roller station (1) comprising a frame-like structure (3) which supports a roller or idler (4) with continuous friction on the edge (B) of the conveyor belt (2) at both its left end (El) and its right end (ED) located on a conveyor belt (2), arranged using the existing structures (5) of said conveyor belt (2), the centering roller station (1) allows maintaining the correct position (6) of displacement of the conveyor belt (2) through its displacement, by means of the centering rollers or idlers (4),The centering roller station (1) exerts mechanical friction work on the conveyor belt (2) by means of cylindrical centering rollers (4) that ensure the constant alignment of the conveyor belt (2). These rollers are arranged opposite each other at both the left (L) and right (R) ends of the belt. Each centering roller (4) is positioned at a 45° angle and supported by a rolling shaft (7) around which it rotates. The shaft is made of high-carbon steel and mounted on ball bearings (8) at its ends. Ball bearings have a high load capacity and are less sensitive to misalignment than tapered roller bearings, which are very sensitive to misalignment. The rolling shaft (7) is positioned at a 45° angle and supported between two metal plates.The rolling shaft (7) is inserted inside a cylindrical tube or sleeve (9) made of mild steel, which allows the shaft (7) to roll inside and additionally protects it, so that the centering roller (4) made of HDPE (see figure 9) rotates reliably supported at its ends by the previously mentioned ball bearings (8).

[0061] According to one modality for the support (10) of the centering rollers (4), a rigid upper support (16) made of carbon steel is used, which is supported in a welded manner to a metal pillar (11) of triangular section that receives this upper support cut at its left end (El) with the same triangular shape as the pillar (11) so as to fit snugly and subsequently be welded supported on it, the right end (ED) of the upper metal plate is inclined at 230° and on its surface there is an elongated groove (20) centered with respect to its longitudinal axis, Y axis, which allows fitting and securing by gravity the rolling shaft (7) that supports the centering roller (4).A lower rigid support (14) made of carbon steel, of shorter length, rests on the lower end of the rolling shaft (7) of the centering roller (4), of shorter length, at its left end (El) it is welded again to the pillar of triangular section (11 ), and its free right end supports the lower end (EF) of the rolling shaft (7) in the same way as previously described.

[0062] Figures 8 to 11 illustrate the four configurations of the support system for the centering rollers (4). In the first configuration, Figure 8, the system comprises a joint with radial play (13) only on the lower tensioner (15), i.e., a rigid support (16), and an upper (17) and lower (17a) tensioner with an adjustable spring for the axial play of the conveyor belt (2) and additionally to support loads. These tensioners are attached to the metal support (10) by means of bushing-type joints with radial play (13). This joint does not have a cylindrical portion in the form of a hollow central shaft (18) with free play.

[0063] In Figure 9, the second modality of the support system comprises a joint with radial play (13) in both the upper tensioner (17) with spring and the lower tensioner (17a) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally to support loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint has a cylindrical portion in the form of a hollow central shaft (18) with a larger diameter than the length of the upper (17) and lower (17a) spring supports, with free play, in the center of the hollow shaft (18) in order to allow the operation of a cut-off and alignment switch (19), this second modality can be located in the area of ​​the drive pulley or in critical areas, this second modality incorporates basic sensors for monitoring and manual adjustments, monitoring of the wear of the parts and pieces, objective for the medium-sized company.

[0064] In Figure 10, the third modality of the support system comprises a bushing-type joint with radial play (13), and three tensioners for longer rollers: the upper tensioner (17) with spring, the intermediate tensioner (not shown) with spring, and the lower tensioner (17a) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally to support loads, joined to the metal support (10) by means of bushing-type joints with radial play (13). This joint has a cylindrical portion in the form of a hollow central shaft (18) with a larger diameter than the length of the upper (17) and lower (17a) spring-loaded supports, with free play. This hollow shaft (18) allows the operation of a cut-off switch and sensors (19) inside. This third modality incorporates advanced sensors and automatic adjustments, automatic alignment of the conveyor belt (2), preventive maintenance alerts, and is aimed at large companies with critical operations.

[0065] In Figure 11, the fourth mode of the support system comprises a joint with radial play (13), and three longer roller tensioners (4), the upper tensioner (17) with spring, the intermediate tensioner (17a) with spring and the lower tensioner (17b) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally support loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint has a cylindrical portion in the form of a hollow central shaft (18) with a larger diameter than the length of the upper (17) and lower (17a) spring supports, with free play, this hollow shaft (18) allows the operation of a cut-off switch and sensors (19) inside, this fourth mode integrates centralized management and monitoring systems, reducing operator intervention, targeting advanced and technological industries.Although not shown, the centering roller station (1) incorporates a conveyor belt tensioning system (2) that allows for independent tensioning at each right (ED) and left (El) end. This system includes springs to stabilize loads on the conveyor belt (2) and prevent misalignment during load transfer. This avoids interventions that could disrupt material flow on the conveyor belt (2) surface, both in terms of the space used across its width and height. This configuration is particularly important because misalignment could cause the conveyor belt (2) to lift along the path of the centering roller (4), potentially resulting in premature system shutdown.

[0066] The centering roller station (1) is designed to be integrated and adapted to existing systems and structures (5), incorporating pre-existing safety systems such as belt cut sensors, belt deviation sensors (19) (see Figure 19), and self-aligning stations. These are located inside the cylindrical portion, forming a hollow central shaft (18), for increased system efficiency and protection. The centering roller station (1) also includes automatic protection to detect critical misalignment of the conveyor belt (2) with respect to its longitudinal axis (Y). This is achieved through switches / sensors (19) that automatically stop the equipment before critical misalignments occur, thus preventing damage to the conveyor system and minimizing the costs associated with unplanned conveyor belt (2) downtime.

[0067] Industrial Application

[0068] The present invention relates to a station for centering or aligning a mining conveyor belt to prevent its deviation from its longitudinal axis (Y-axis). Depending on its application, it finds use in industry, particularly in the metalworking industry, the high-strength plastics industry (for manufacturing centering rollers), the high-strength rubber industry, the metal industry (for manufacturing various profiles), and the electrical industry. Reference List

[0069] B Strap edge

[0070] The far left

[0071] ED Far right

[0072] EF Lower extreme

[0073] ES Upper extreme

[0074] Existing Polín P

[0075] R Existing removable protective grille

[0076] And longitudinal axis of conveyor belt

[0077] 1 Centering roller station

[0078] 2 Conveyor belt

[0079] 3 Frame-like structure

[0080] 4 Centering roller or pulley

[0081] 5 Existing structure

[0082] 6 Correct position belt displacement

[0083] 7. Center line

[0084] 8 Ball bearing

[0085] 9 Cylindrical sleeve tube for centering idler

[0086] 10 Upper support, centering pole, metal bracket

[0087] 11 Metal pillar with triangular section

[0088] 12 Crossbeam

[0089] 13 Hub-type union with radial play

[0090] 14 Lower support

[0091] 15 T lower sensor without spring

[0092] 16 Rigid support first modality

[0093] 17 Upper spring tensioner

[0094] 17a Intermediate spring tensioner

[0095] 17b Lower spring tensioner

[0096] 18 Cylindrical portion in the form of a hollow central axis

[0097] 19 Cut-off and alignment switch / sensor

[0098] 20 Elongated groove for purlin

Claims

AMENDED CLAIMS received by the International Bureau on April 4, 2025 (04.04.2025) Claims

1. A self-contained centering roller station (1) located on a conveyor belt (2), CHARACTERIZED in that it comprises a frame-like structure (3) supporting a system of centering rollers (4), arranged opposite each other on both edges of the conveyor belt (2), wherein each centering roller (4) is positioned at a 45° angle, mounted on a rolling axle (7), which is housed within a cylindrical metal sleeve (9), supported on ball bearings (8), and wherein said rollers exert structurally regulated continuous friction on the edges (B) of the conveyor belt (2), allowing its alignment to be maintained throughout the operation. Unlike conventional self-aligning systems that only act in response to deviation, the centering roller station (1) further comprises scalable versions that integrate tensioners, sensors,and automatic monitoring for preventive alignment, in four different modes where in:, - In the first modality, the system comprises a joint with radial play (13) only in the lower tensioner (15), i.e., a rigid support (16), and an upper (17) and lower (17a) tensioner provided with a spring with adjustment for the axial play of the conveyor belt (2) and additionally to support loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint does not have a cylindrical portion in the form of a hollow central shaft (18) with free play, - the second modality is identical to the first modality with the exception that the bushing-type joint has a cylindrical portion in the form of a hollow central shaft (18) with a larger diameter than the length of the upper (17) and lower (17a) spring supports, with free play, in the center of the hollow shaft support (18) so as to allow the operation of a cut-off and alignment switch (19), - the third modality comprises a bushing-type joint with radial play (13), and three tensioners for longer rollers, The upper tensioner (17) with spring, the intermediate tensioner (not shown) with spring and the lower tensioner (17a) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally support loads, attached to the metal support (10), this third mode incorporates advanced sensors and automatic adjustments, automatic alignment of the conveyor belt (2), - The fourth modality, identical to the previous ones, integrates centralized management and monitoring systems.

2. The centering roller station (1), according to claim 1, CHARACTERIZED in that for the upper support (10) of the centering roller (4) a rigid upper support (16) made of carbon steel is used, which is supported by welding to a metal pillar (11) of triangular section that receives this upper support cut at its left end (El) with the same triangular shape as the pillar (11) so as to fit snugly and subsequently be welded supported thereon, the right end (ED) of the upper metal plate is inclined at 230° and on its surface there is located an elongated groove (20) centered with respect to its longitudinal axis, Y-axis, which allows fitting and securing by gravity the rolling shaft (7) that supports the centering roller (4), a rigid lower support (14) made of carbon steel, of shorter length, supports the lower end of the rolling shaft (7) of the centering roller (4).

3. The centering roller station (1), according to claim 2, CHARACTERIZED in that the support system for the rollers comprises four modes, wherein in the first mode the system comprises a joint with radial play (13) only on the lower tensioner (15), namely a rigid support (16), and an upper (17) and lower (17a) tensioner with spring adjustment for the axial play of the conveyor belt (2) and additionally supporting loads, joined to the metal support (10) by means of bushing-type joints with radial play (13).

4. The centering roller station (1), according to claim 3, CHARACTERIZED in that the second The support system modality includes a radial play joint (13) on both the upper spring tensioner (17) and the lower spring tensioner (17a), with adjustment for the axial play of the conveyor belt (2) and additionally supporting loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint has a cylindrical portion in the form of a hollow central shaft (18) of greater diameter than the length of the upper (17) and lower (17a) spring supports, with free play, in the center of the hollow shaft support (18) so as to allow the operation of a cut-off and alignment switch (19).

5. The centering roller station (1), according to claim 4, CHARACTERIZED in that the third modality for the support system includes, a bushing-type joint with radial play (13), and three tensioners for longer rollers, the upper tensioner (17) with spring, the intermediate tensioner (not shown) with spring and the lower tensioner (17a) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally supporting loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint has a cylindrical portion in the form of a hollow central shaft (18) of greater diameter than the length of the upper (17) and lower (17a) spring supports, with free play, this hollow shaft (18) allows the operation of a cut-off switch and sensors (19) inside.

6. The centering roller station (1), according to claim 5, CHARACTERIZED in that the fourth embodiment for the support system comprises a joint with radial play (13), and three longer roller tensioners (4), the upper tensioner (17) with spring, the intermediate tensioner (17a) with spring and the lower tensioner (17b) with spring, with adjustment for the axial play of the conveyor belt (2) and additionally supporting loads, joined to the metal support (10) by means of bushing-type joints with radial play (13), this joint having a cylindrical portion in the form of a hollow central shaft (18) of greater diameter than the length of the upper (17) and lower (17a) spring-loaded supports, with free play, this The hollow shaft (18) allows the operation of a cut-off switch and sensors (19) inside.

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