Conveyor belt controlling system and method for controlling a conveyor belt controlling system

Abstract

A conveyor belt controlling system and method for tension adjustment and alignment of an endless conveyor belt extending in a longitudinal direction between a drive roller and an idler roller. The conveyor belt controlling system comprises a belt tensioning unit attached to a conveyor frame and a belt tracking unit attached to the belt tensioning unit. The idler roller is attached to the belt tracking unit. The belt tensioning unit comprises a support structure movably arranged relative to the conveyor frame in the longitudinal direction for establishing a longitudinal movement of the idler roller, enabling tension adjustment of the conveyor belt. The belt tracking unit comprises a first side structure and a second side structure, and the idler roller is arranged between the first side structure and the second side structure. Each of the first side structure and the second side structure is individually movable relative to the support structure in the longitudinal direction for establishing a tilting position of the idler roller enabling alignment of the conveyor belt.

Description

[0001] CONVEYOR BELT CONTROLLING SYSTEM AND METHOD FOR CONTROLLING A CONVEYOR BELT CONTROLLING SYSTEM

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to a conveyor belt controlling system configured for tension adjustment and alignment of an endless conveyor belt extending in a longitudinal direction between a drive roller and an idler roller. The disclosure further relates to a method for controlling a conveyor belt controlling system.

[0004] BACKGROUND

[0005] Conveyor systems are commonly used for transporting various types of articles. Conveyor systems may be arranged as flat belt conveyors. A flat belt conveyor is a type of conveyance system that utilizes an endless conveyor belt to transport articles by moving the conveyor belt between two roller shafts. One of these roller shafts is typically connected to and powered by a gear motor, which causes the roller shaft to rotate. This powered roller shaft is commonly referred to as a drive roller. The other roller shaft is passive, and is commonly referred to as an idler roller. Power is transferred from the drive roller to the conveyor belt through friction between the drive roller surface and the surface of the conveyor belt. This friction can be increased by increasing the amount of surface contact between the conveyor belt and the drive roller and / or increasing the tension of the conveyor belt.

[0006] These types of conveyors are typically used in applications requiring light to medium duty article handling. The conveyor belt can be arranged as a belt structure made from various materials, depending on the requirements of the articles being transported. Conveyor belts can also be designed with features like grip surfaces for inclines, or food-grade qualities for specific industries.

[0007] There are two common challenges that are encountered in designing a conveyor. The first challenge is the need to take up excess belt slack between the two roller shafts. To allow for the installation of the conveyor belt over the two roller shafts, the beltmust be slightly larger than the belt travelling distance over the two roller shafts. However, after installation of the conveyor belt over the roller shafts, the belt will be too long to effectively transfer power from the drive shaft into the belt through friction, and there is a need for adjusting the tension in the conveyor belt. The second challenge is the tendency of the conveyor belt to travel away from the centreline of the conveyor, either to the left or to the right. Conveyor belt tracking refers to the process of aligning and controlling a conveyor belt to ensure it follows its intended path. This practice prevents the conveyor belt from drifting off to one side and maintains proper material flow by keeping the belt centred on the roller shafts throughout its run. A flat conveyor belt will naturally travel towards the side of the conveyor with the lowest tension.

[0008] A flat conveyor belt can travel off centre for a few reasons. For example if a conveyor frame that secures the two roller shafts is slightly out of alignment, this will cause the roller shafts to not be parallel with each other. The result is uneven tension applied to the conveyor belt. Another example is if the conveyor is loaded unevenly. This will cause higher conveyor belt tension on the side of the conveyor belt that has the highest weight.

[0009] Commonly, the conveyor belt tension and alignment is adjusted through complicated tensioning and tracking arrangements, such as threaded screw adjustment mechanisms with threaded shafts that are holding the idler roller. A notable disadvantage of this threaded screw adjustment design occurs when a conveyor belt is replaced. Any time a new conveyor belt is installed, the tracking adjustment must be completely redone. Additionally, belt installation and tracking adjustment can be time consuming since the retaining nut and locking nut must be threaded up to several inches on the threaded shaft.

[0010] There is thus a need for an improved conveyor belt system, where the tension and alignment of the conveyor belt can be easily adjusted.

[0011] SUMMARY

[0012] An object of the present disclosure is to provide a conveyor belt controlling system and a method for controlling a conveyor belt controlling system, where the previouslymentioned problems are avoided. This object is at least partly achieved by the features of the independent claims. The dependent claims contain further developments of the conveyor belt controlling system and the method for controlling a conveyor belt controlling system.

[0013] The disclosure concerns a conveyor belt controlling system configured for tension adjustment and alignment of an endless conveyor belt extending in a longitudinal direction between a drive roller and an idler roller. The conveyor belt controlling system comprises a belt tensioning unit attached to a conveyor frame and a belt tracking unit attached to the belt tensioning unit. The idler roller is attached to the belt tracking unit. The belt tensioning unit comprises a support structure movably arranged relative to the conveyor frame in the longitudinal direction for establishing a longitudinal movement of the idler roller, enabling tension adjustment of the conveyor belt. The belt tracking unit comprises a first side structure and a second side structure, and the idler roller is arranged between the first side structure and the second side structure. Each of the first side structure and the second side structure is individually movable relative to the support structure in the longitudinal direction for establishing a tilting position of the idler roller enabling alignment of the conveyor belt.

[0014] Advantages with these features are that the conveyor belt controlling system is efficiently adjusting both the tension and alignment of the conveyor belt. The conveyor belt controlling system is simple in construction through the movable support structure and the side structures, and the tension and alignment of the conveyor belt can be adjusted by displacing these structures. By moving the support structure relative to the conveyor frame in the longitudinal direction, the tension of the conveyor belt is easily adjusted. By individually moving the side structures relative to the support structure in the longitudinal direction the tilting position of the idler roller is established for a simple and efficient alignment of the conveyor belt. The conveyor belt controlling system further enables time efficient installation of the conveyor belt and simple tension adjustment and alignment adjustment of the conveyor belt after installation, as well as during operation of the conveyor.

[0015] In one embodiment, the belt tensioning unit comprises a belt tensioner shaft with a tensioner pinion rotatably connected to the conveyor frame and a toothed tensioner rack attached to the support structure. The tensioner pinion is in threaded engagement with the tensioner rack. Upon a rotational displacement of the belttensioner shaft with the tensioner pinion, the tensioner rack is configured for displacing the support structure in the longitudinal direction relative to the conveyor frame. Through the threaded engagement between the tensioner pinion and the tensioner rack, the tensioner rack is efficiently displacing the support structure in the longitudinal direction relative to the conveyor frame upon the rotational displacement of the belt tensioner shaft with the tensioner pinion. By rotating the tensioner shaft in opposite directions, the support structure can be displaced in the longitudinal direction both away from and towards the conveyor frame with the drive roller for an efficient tension adjustment of the conveyor belt.

[0016] In one embodiment, the tensioner rack is extending in the longitudinal direction and the belt tensioner shaft is extending in a lateral direction. This is enabling a smooth transfer of movement between the tensioner pinion and the tensioner rack. The rotational movement of the tensioner shaft is directly transferred to the tensioner pinion, since the tensioner pinion is attached to the tensioner shaft. The threaded engagement between the tensioner pinion and the tensioner rack is establishing a translational movement of the tensioner rack in the longitudinal direction.

[0017] In one embodiment, the belt tensioning unit comprises an actuator drivingly connected to the belt tensioner shaft, and the actuator is configured for rotatably displacing the belt tensioner shaft. The actuator is used for a simple and reliable adjustment of the tension of the conveyor belt.

[0018] In one embodiment, the actuator is a manually operated actuating mechanism connected to the belt tensioner shaft. The actuator may be arranged as an Allen wrench or similar tool that is temporarily brought in engagement with the belt tensioner shaft upon adjustment of the belt tension. The belt tensioner shaft is suitably arranged with a hexagonal recess for the Allen key, or similar arrangement for other suitable tools. The actuator may instead be arranged as a lever or a hand wheel attached to the belt tensioner shaft.

[0019] In one embodiment, the actuator is arranged as an electric actuator drivingly connected to the belt tensioner shaft. The belt tensioning unit comprises a belt tension sensor configured for detecting a belt tension level of the conveyor belt and a belt tension control unit connected to the belt tension sensor and the actuator. The belt tension control unit is configured for controlling the belt tension level based on inputfrom the belt tension sensor, and the belt tension control unit is configured for adjusting the belt tension level by means of the actuator based on the detected belt tension level by the belt tension sensor. The adjustment of the tension of the conveyor belt is achieved by the electric actuator, and the belt tensioner shaft is with this configuration arranged to rotate through actuation from the electric actuator. The actuator is suitably an electric motor, where a drive shaft of the electric motor is directly connected or indirectly connected to the belt tensioner shaft. A gear unit or similar arrangement may be arranged between the belt tensioner shaft and the actuator if desired. The belt tension control unit is efficiently controlling the belt tension level based on input from the belt tension sensor, and the belt tension control unit is then adjusting the belt tension level by means of the actuator based on the detected belt tension level by the belt tension sensor. The belt tension sensor may be any suitable sensor that is detecting the belt tension level in the conveyor belt. Suitable sensors are for example pressure sensors, load cell sensors, optical sensors, or inductive sensors.

[0020] In one embodiment, the belt tracking unit comprises a first displacement mechanism arranged between the support structure and the first side structure. The first displacement mechanism is configured for displacing the first side structure in the longitudinal direction relative to the support structure. The belt tracking unit comprises a second displacement mechanism arranged between the support structure and the second side structure. The second displacement mechanism is configured for displacing the second side structure in the longitudinal direction relative to the support structure. The displacement mechanisms are used fora simple and efficient individual displacement of the respective side structures relative to the support structure.

[0021] In one embodiment, the first displacement mechanism comprises a first bevel gear set attached to the support structure. The first bevel gear set is connected to a first threaded coupling extending between the support structure and the first side structure, where the first threaded coupling is in threaded engagement with the first side structure. Upon a rotational displacement of the first bevel gear set, the first threaded coupling is rotated for displacing the first side structure in the longitudinal direction relative to the support structure. The second displacement mechanism comprises a second bevel gear set attached to the support structure. The second bevel gear set is connected to a second threaded coupling extending between thesupport structure and the second side structure, where the second threaded coupling is in threaded engagement with the second side structure. Upon a rotational displacement of the second bevel gear set, the second threaded coupling is rotated for displacing the second side structure in the longitudinal direction relative to the support structure. The bevel gear sets each comprises a first gear and a second gear, where the gears suitably are configured as cone shaped gears that transmit motion between two shafts having intersecting extensions. The second gears of the respective bevel gear set is drivingly connected to the threaded couplings, and the threaded couplings are in threaded engagement with the corresponding side structures. The second gear is transferring a rotational movement to a threaded shaft of the threaded coupling, and the threaded shaft is in threaded engagement with a nut or similar threaded structure attached to the side structure. The rotational movement of the second gear is established by rotating the first gear. When a rotational movement is transferred to the threaded shaft from the second gear, the side structure is displaced in the longitudinal direction through the threaded engagement between the threaded shaft and the nut. By rotating the first gear in opposite directions, the side structure can be displaced in the longitudinal direction both away from and towards the support structure for an efficient alignment of the conveyor belt.

[0022] In one embodiment, the belt tracking unit comprises a first actuating device drivingly connected to the first bevel gear set and a second actuating device drivingly connected to the second bevel gear set. The first actuating device is configured for rotatably displacing the first bevel gear set and the second actuating device is configured for rotatably displacing the second bevel gear set. The actuating devices are used for a simple and reliable displacement of the respective bevel gear sets.

[0023] In one embodiment, the first actuating device is a manually operated actuating mechanism connected to the first bevel gear set and the second actuating device is a manually operated actuating mechanism connected to the second bevel gear set. The actuating devices may be arranged as Allen wrenches or similar tools that are temporarily brought in engagement with the first gear of the respective bevel gear sets. The first gear is suitably arranged with a hexagonal recess for the Allen key, or similar arrangement for other suitable tools. The actuating devices may alternatively be arranged as levers or hand wheels attached to the respective bevel gear sets.In one embodiment, the belt tracking unit comprises a belt alignment sensor configured for detecting a belt alignment of the conveyor belt. The first actuating device is arranged as an electric actuator drivingly connected to the first bevel gear set, and the second actuating device is arranged as an electric actuator drivingly connected to the second bevel gear set. The belt tracking unit comprises a belt alignment control unit connected to the belt alignment sensor, the first actuating device, and the second actuating device. The belt alignment control unit is configured for controlling the belt alignment based on input from the belt alignment sensor. The belt alignment control unit is configured for adjusting the belt alignment by means of the first actuating device and / or the second actuating device based on the detected belt alignment by the belt alignment sensor. The belt alignment sensor may for example be arranged as an optical sensor, a mechanical sensor, or an inductive sensor. The adjustment of the belt alignment of the conveyor belt is achieved by means of the first actuating device and the second actuating device respectively. When adjusting the belt alignment of the conveyor belt, the first bevel gear set is rotatably displaced by the first actuating device, and / or the second bevel gear set is rotatably displaced by the second actuating device.

[0024] The disclosure further concerns a method for controlling a conveyor belt controlling system configured for tension adjustment and alignment of an endless conveyor belt extending in a longitudinal direction between a drive roller and an idler roller. The conveyor belt controlling system comprises a belt tensioning unit attached to a conveyor frame and a belt tracking unit attached to the belt tensioning unit. The idler roller is attached to the belt tracking unit. The belt tensioning unit comprises a support structure movably arranged relative to the conveyor frame in the longitudinal direction, and the belt tracking unit comprises a first side structure and a second side structure. The idler roller is arranged between the first side structure and the second side structure. The method comprises the steps: adjusting the tension of the conveyor belt by establishing a longitudinal movement of the idler roller through displacement of the support structure relative to the conveyor frame in the longitudinal direction; and / or aligning the conveyor belt by establishing a tilting position of the idler roller through individual displacement of the first side structure and / or the second side structure relative to the support structure in the longitudinal direction.Advantages with the method are that the conveyor belt controlling system is efficiently adjusting both the tension and alignment of the conveyor belt. The conveyor belt controlling system is simple in construction through the movable support structure and the side structures, and the tension and alignment of the conveyor belt can be adjusted. By moving the support structure relative to the conveyor frame in the longitudinal direction, the tension of the conveyor belt is easily adjusted. By individually moving the side structures relative to the support structure in the longitudinal direction the tilting position of the idler roller is established for a simple and efficient alignment of the conveyor belt. The conveyor belt controlling system further enables time efficient installation of a conveyor belt and simple tension adjustment and alignment adjustment of the conveyor belt after installation, as well as during operation of the conveyor.

[0025] In one embodiment, the belt tensioning unit comprises a belt tensioner shaft with a tensioner pinion rotatably connected to the conveyor frame and a toothed tensioner rack attached to the support structure. The tensioner pinion is in threaded engagement with the tensioner rack. The method further comprises the step: displacing the support structure in the longitudinal direction relative to the conveyor frame by the tensioner rack through a rotational displacement of the belt tensioner shaft with the tensioner pinion. Through the threaded engagement between the tensioner pinion and the tensioner rack, the tensioner rack is efficiently displacing the support structure in the longitudinal direction relative to the conveyor frame upon the rotational displacement of the belt tensioner shaft with the tensioner pinion. By rotating the tensioner shaft in opposite directions, the support structure can be displaced in the longitudinal direction both away from and towards the conveyor frame with the drive roller for an efficient tension adjustment of the conveyor belt. The rotational movement of the tensioner shaft is directly transferred to the tensioner pinion, since the tensioner pinion is attached to the tensioner shaft. The threaded engagement between the tensioner pinion and the tensioner rack is establishing a translational movement of the tensioner rack in the longitudinal direction.

[0026] In one embodiment, the belt tensioning unit comprises an actuator drivingly connected to the belt tensioner shaft. The method further comprises the step: rotatably displacing the belt tensioner shaft by the actuator. The actuator is enabling a simple and reliable adjustment of the tension of the conveyor belt.In one embodiment, the actuator is arranged as an electric actuator drivingly connected to the belt tensioner shaft. The belt tensioning unit comprises a belt tension sensor configured for detecting a belt tension level of the conveyor belt and a belt tension control unit connected to the belt tension sensor and the actuator. The method further comprises the step: controlling the belt tension level by the belt tension control unit based on input from the belt tension sensor, wherein the belt tension control unit is adjusting the belt tension level by means of the actuator based on the detected belt tension level by the belt tension sensor. The adjustment of the tension of the conveyor belt is achieved by the electric actuator, and the belt tensioner shaft is with this configuration arranged to rotate through actuation from the electric actuator. The actuator is suitably an electric motor, where a drive shaft of the electric motor is directly connected or indirectly connected to the belt tensioner shaft. A gear unit or similar arrangement may be arranged between the belt tensioner shaft and the actuator if desired. The belt tension control unit is efficiently controlling the belt tension level based on input from the belt tension sensor, and the belt tension control unit is then adjusting the belt tension level by means of the actuator based on the detected belt tension level by the belt tension sensor. The belt tension sensor may be any suitable sensor that is detecting the belt tension level in the conveyor belt. Suitable sensors are for example pressure sensors, load cell sensors, optical sensors, or inductive sensors.

[0027] In one embodiment, the belt tracking unit comprises a first displacement mechanism arranged between the support structure and the first side structure, and a second displacement mechanism arranged between the support structure and the second side structure. The method further comprises the steps: displacing the first side structure in the longitudinal direction relative to the support structure by the first displacement mechanism; and / or displacing the second side structure in the longitudinal direction relative to the support structure by the second displacement mechanism. The displacement mechanisms are used for a simple and efficient individual displacement of the respective side structures relative to the support structure.

[0028] In one embodiment, the first displacement mechanism comprises a first bevel gear set attached to the support structure. The first bevel gear set is connected to a first threaded coupling extending between the support structure and the first sidestructure, and the first threaded coupling is in threaded engagement with the first side structure. The second displacement mechanism comprises a second bevel gear set attached to the support structure. The second bevel gear set is connected to a second threaded coupling extending between the support structure and the second side structure, and the second threaded coupling is in threaded engagement with the second side structure. The method further comprises the steps: rotating the first threaded coupling through a rotational displacement of the first bevel gear set for displacing the first side structure in the longitudinal direction relative to the support structure; and / or rotating the second threaded coupling through a rotational displacement of the second bevel gear set for displacing the second side structure in the longitudinal direction relative to the support structure. The bevel gear sets each comprises a first gear and a second gear, where the gears suitably are configured as cone shaped gears that transmit motion between two shafts having intersecting extensions. The second gears of the respective bevel gear sets are drivingly connected to the threaded couplings, and the threaded couplings are in threaded engagement with the corresponding side structures. The second gear is transferring a rotational movement to a threaded shaft of the threaded coupling, and the threaded shaft is in threaded engagement with a nut or similar threaded structure attached to the side structure. The rotational movement of the second gear is established by rotating the first gear. When a rotational movement is transferred to the threaded shaft from the second gear, the side structure is displaced in the longitudinal direction through the threaded engagement between the threaded shaft and the nut. By rotating the first gear in opposite directions, the side structure can be displaced in the longitudinal direction both away from and towards the support structure for an efficient alignment of the conveyor belt.

[0029] In one embodiment, the belt tracking unit comprises a first actuating device drivingly connected to the first bevel gear set and a second actuating device drivingly connected to the second bevel gear set. The method further comprises the steps: rotatably displacing the first bevel gear set by the first actuating device; and / or rotatably displacing the second bevel gear set by the second actuating device. The actuating devices are used for a simple and reliable displacement of the respective bevel gear sets.In one embodiment, the belt tracking unit comprises a belt alignment sensor configured for detecting a belt alignment of the conveyor belt. The first actuating device is arranged as an electric actuator drivingly connected to the first bevel gear set and the second actuating device is arranged as an electric actuator drivingly connected to the second bevel gear set. The belt tracking unit comprises a belt alignment control unit connected to the belt alignment sensor, the first actuating device, and the second actuating device. The method further comprises the steps: controlling the belt alignment by the belt alignment control unit based on input from the belt alignment sensor, wherein the belt alignment control unit is adjusting the belt alignment by means of the first actuating device and / or the second actuating device based on the detected belt alignment by the belt alignment sensor. The belt alignment sensor may for example be arranged as an optical sensor, a mechanical sensor, or an inductive sensor. The adjustment of the belt alignment of the conveyor belt is achieved by means of the first actuating device and the second actuating device respectively. When adjusting the belt alignment of the conveyor belt, the first bevel gear set is rotatably displaced by the first actuating device, and / or the second bevel gear set is rotatably displaced by the second actuating device.

[0030] BRIEF DESCRIPTION OF DRAWINGS

[0031] The disclosure will be described in detail in the following, with reference to the attached drawings, in which

[0032] Fig. 1 shows schematically, in a perspective view, a conveyor having an endless conveyor belt extending in a longitudinal direction between a drive roller and an idler roller, where the conveyor comprises a conveyor belt controlling system configured for tension adjustment and alignment of the conveyor belt,

[0033] Fig. 2a-b show schematically, in perspective views, the conveyor belt controlling system comprising a belt tensioning unit attached to a conveyor frame and a belt tracking unit attached to the belt tensioning unit,

[0034] Fig 3a-c show schematically, in views from above, the belt tensioning unit in different operating positions,Fig 4a-c show schematically, in views from above, the belt tracking unit in different operating positions, and

[0035] Fig. 5 shows schematically, in a perspective view, an alternative embodiment of the conveyor belt controlling system comprising a belt tensioning unit attached to a conveyor frame and a belt tracking unit attached to the belt tensioning unit.

[0036] DESCRIPTION OF EXAMPLE EMBODIMENTS

[0037] Various aspects of the disclosure will hereinafter be described in conjunction with the appended drawings to illustrate and not to limit the disclosure, wherein like designations denote like elements, and variations of the described aspects are not restricted to the specifically shown embodiments, but are applicable on other variations of the disclosure.

[0038] Figure 1 schematically shows a conveyor C comprising an endless conveyor belt B extending in a longitudinal direction DLO between a drive roller RD and an idler roller Ri. The conveyor C further has a width extension in a lateral direction DLA, as shown in the figure. The length of the conveyor belt B in the longitudinal direction DLO and the width of the conveyor belt B in the lateral direction DLA may vary depending on the type of conveyor C.

[0039] The drive roller RD is arranged as a powered roller shaft and is suitable connected to a non-illustrated drive arrangement, such as a gear motor causing the roller shaft to rotate. A gear motor is a type of electric motor that combines an electric motor with a gearbox. The gearbox contains a set of gears that reduces the speed of the electric motor and increases its torque. This allows the gear motor to deliver more power at lower speeds, making it ideal for applications where high torque is required. The idler roller Ri is arranged as a passive roller shaft. Power is transferred from the drive roller RD to the conveyor belt B through friction between the surface of the drive roller RD and the surface of the conveyor belt B.

[0040] The shown conveyor C is typically used in applications requiring light to medium duty article handling. The conveyor belt B can be arranged as a belt structure made fromvarious materials, such as rubber, polyvinyl chloride (PVC), or polyurethane (Pll), depending on the requirements of the articles being transported.

[0041] The conveyor belt B is supported by a conveyor frame F and a conveyor belt controlling system S, as shown in figure 1. The conveyor belt controlling system S is attached to the conveyor frame F. The conveyor frame F is suitably arranged as a rigid structure that efficiently is handling the loads from the conveyor belt B and the articles transported on the conveyor belt B. The drive roller RD is attached to the conveyor frame F and the idler roller Ri is attached to the conveyor belt controlling system S. The conveyor belt controlling system S is configured for tension adjustment and alignment of the conveyor belt B, as will be further described below.

[0042] The conveyor belt controlling system S is shown in detail in figures 2a-b. In figure 2b, the belt controlling system S is shown without the conveyor belt B for illustrative purposes. The conveyor belt controlling system S comprises a belt tensioning unit 1 attached to the conveyor frame F, and a belt tracking unit 2 attached to the belt tensioning unit 1. The idler roller Ri is attached to the belt tracking unit 2.

[0043] The belt tensioning unit 1 is used for adjusting a belt tension level LBT of the conveyor belt B. By adjusting the tension of the conveyor belt B, the belt tensioning unit 1 is taking up excess belt slack between the drive roller RD and the idler roller Ri. The friction between the surface of the drive roller RD and the surface of the conveyor belt B can be increased by increasing the belt tension level LBT of the conveyor belt B, or decreased by decreasing the belt tension level LBT of the conveyor belt B. The tension of the conveyor belt B is adjusted by the belt tensioning unit 1 through changing the distance between the drive roller RD and the idler roller Ri in the longitudinal direction DLO, by moving the idler roller Ri in the longitudinal direction DLO relative to the drive roller RD.

[0044] Further, to allow for the installation of the conveyor belt B over the drive roller RD and the idler roller Ri, the belt tensioning unit 1 can be used for decreasing the distance between the drive roller RD and the idler roller Ri in the longitudinal direction DLO. After installation of the conveyor belt B over the drive roller RD and the idler roller Ri, the belt will be too long to effectively transfer power from the drive roller RD into the belt through friction, and the belt tensioning unit 1 is then used for increasing the distance between the drive roller RD and the idler roller Ri in the longitudinal direction DLO.The belt tracking unit 2 is used for adjusting a belt alignment AB of the conveyor belt B. Conveyor belt tracking refers to the process of aligning and controlling the conveyor belt B, to ensure that the conveyor belt follows its intended path when operated. The conveyor belt B will naturally travel towards the side with the lowest tension, and one or more of the drive roller RD and the idler roller Ri may further be slightly out of alignment causing them not to be parallel with each other. By properly adjusting the alignment of the conveyor belt B, the conveyor belt B is prevented from drifting off to one side and instead kept centred on the drive roller RD and the idler roller Ri throughout its run. A proper belt alignment AB will result in even tension applied to the conveyor belt B. The alignment of the conveyor belt B is adjusted by the belt tracking unit 2 through changing the angular relationship between the idler roller Ri and the drive roller RD, by arranging the idler roller Ri in a tilting position relative to the drive roller RD.

[0045] With the expression tilting position is meant that the rotational axis of the idler roller Ri is adjusted relative to the rotational axis of the drive roller RD. In the shown embodiment, the rotational axis of the drive roller RD is extending in the lateral direction DLA. If also the rotational axis of the idler roller Ri is extending in the lateral direction DLA, it may be tilted to a position arranged at an angle to the lateral direction DLA, such that the rotational axis of the idler roller Ri is non-parallel to the rotational axis of the drive roller RD. If instead the rotational axis of the idler roller Ri is extending non-parallel to the lateral direction DLA, it may be tilted to a position parallel to the lateral direction DLA or to another position non-parallel to the lateral direction DLA.

[0046] The belt tensioning unit is schematically illustrated in figures 2a-b and 3a-c. In figures 3a-c, the conveyor C is shown without the conveyor belt B for illustrative purposes. The belt tensioning unit 1 comprises a support structure 1a movably arranged relative to the conveyor frame F in the longitudinal direction DLO for establishing a longitudinal movement of the idler roller Ri. The support structure 1a is suitably arranged as a rigid frame structure that is movably attached to the conveyor frame F, where the support structure 1a is firmly supporting the belt tracking unit 2. The movable arrangement of the support structure 1a relative to the conveyor frame F is enabling tension adjustment of the conveyor belt B, and the idler roller Ri and the belt tracking unit 2 are moving together with the support structure 1a when changing the belt tension level LBT. Suitably, the support structure 1a is slidingly attached to the conveyor frameF on opposite lateral sides, as understood from figures 3a-c. The conveyor frame F may be arranged with grooves or similar structures that are enabling a sliding connection between the support structure 1a and the conveyor frame F. Slide bearings, linear ball bearings, or similar arrangements, may be arranged between the support structure 1a and the conveyor frame F for an efficient displacement of the support structure 1a relative to the conveyor frame F.

[0047] The position of the support structure 1a shown in figure 3a is for example suitable when installing a new conveyor belt B, since the support structure 1a is arranged as close as possible to the conveyor frame F, with a minimum distance in the longitudinal direction DLO between the drive roller RD and the idler roller Ri.

[0048] By moving the support structure 1a in the longitudinal direction DLO away from the drive roller RD, such as from the position shown in figure 3a to the position in figure 3b, the idler roller Ri is displaced away from the drive roller RD for increasing the belt tension level LBT of the conveyor belt B. By moving the support structure 1a in the longitudinal direction DLO away from the drive roller RD, the distance between the idler roller Ri and the drive roller RD in the longitudinal direction DLO is increasing for establishing the increased belt tension by stretching out the conveyor belt B in the longitudinal direction DLO.

[0049] From the position of the support structure 1a in the longitudinal direction DLO shown in figure 3b, the support structure 1a could be moved in the longitudinal direction DLO further away from the drive roller RD to even further increase the belt tension level LBT, or alternatively be moved in the longitudinal direction DLO towards the drive roller RD to decrease the belt tension level LBT, as indicated with the respective arrows in figure 3c.

[0050] When moving the support structure 1a in the longitudinal direction DLO towards the drive roller RD, the idler roller Ri is displaced towards the drive roller RD for decreasing the belt tension level LBT in the conveyor belt B. By moving the support structure 1a in the longitudinal direction DLO towards the drive roller RD, the distance between the idler roller Ri and the drive roller RD in the longitudinal direction DLO is decreasing for establishing the decreased belt tension.To establish the movement of the support structure 1a in the longitudinal direction DLO, the belt tensioning unit 1 comprises a belt tensioner shaft 1b with a tensioner pinion 1c rotatably connected to the conveyor frame F and a toothed tensioner rack 1 d attached to the support structure 1 a, as shown in figures 3a-c. The tensioner pinion 1c is in threaded engagement with the tensioner rack 1d, and upon a rotational displacement of the belt tensioner shaft 1b with the tensioner pinion 1c, the tensioner rack 1d is displacing the support structure 1a in the longitudinal direction DLO relative to the conveyor frame F. In the shown embodiment, the tensioner rack 1d is extending in the longitudinal direction DLO and the belt tensioner shaft 1b is extending in the lateral direction DLA. By rotating the tensioner shaft 1b in opposite directions, the support structure 1a can be displaced in the longitudinal direction DLO both away from and towards the conveyor frame F with the drive roller RD for an efficient tension adjustment of the conveyor belt B. The rotational movement of the tensioner shaft 1 b is directly transferred to the tensioner pinion 1c, since the tensioner pinion 1c is attached to the tensioner shaft 1b. The threaded engagement between the tensioner pinion 1c and the tensioner rack 1d is establishing a translational movement of the tensioner rack 1 d in the longitudinal direction DLO upon the rotational movement of the tensioner shaft 1b, due to the threaded engagement between the tensioner pinion 1c and the tensioner rack 1d. The belt tracking unit 2 and the idler roller Ri are moving in the longitudinal direction DLO together with the support structure 1a to establish the adjusted distance between the drive roller RD and the idler roller Ri in the longitudinal direction DLO.

[0051] The belt tensioning unit 1 may further comprise an actuator A that is drivingly connected to the belt tensioner shaft 1b. The actuator A is used for rotatably displacing the belt tensioner shaft 1b. The actuator A may be arranged as a manually operated actuating mechanism connected to the belt tensioner shaft 1b, such as an Allen wrench or similar tool that is temporarily brought in engagement with the belt tensioner shaft 1b upon adjustment of the belt tension, as schematically shown in figure 2b. The belt tensioner shaft 1b is suitably arranged with a hexagonal recess for the Allen key, or similar arrangement for other suitable tools. In other embodiments, the actuator A may instead be arranged as a lever or a hand wheel attached to the belt tensioner shaft 1b.The belt tracking unit 2 is schematically illustrated in figures 2a-b and 4a-c. As shown in the figures, the belt tracking unit 2 is attached to the belt tensioning unit 1 and comprises a first side structure 2a and a second side structure 2b used for controlling the belt alignment AB of the conveyor belt B. In figures 4a-c, the conveyor C is shown without the conveyor belt B for illustrative purposes.

[0052] The first side structure 2a and the second side structure 2b are movably attached to the support structure 1a on opposite lateral sides. In the shown embodiment, the first side structure 2a is movably attached to the support structure 1a via a first displacement mechanism 3a, and the second side structure 2b is movably attached to the support structure 1a via a second displacement mechanism 3b, as will be further described below. The idler roller Ri is arranged between the first side structure 2a and the second side structure 2b, and the first side structure 2a and the second side structure 2b are in this way forming a holding structure for the idler roller Ri. The first side structure 2a and the second side structure 2b are suitable arranged as rigid bracket structures for a firm holding of the idler roller Ri. The idler roller Ri is thus held in position relative to the conveyor frame F via the support structure 1a, and the first side structure 2a and second side structure 2b respectively.

[0053] Each of the first side structure 2a and the second side structure 2b is individually movable relative to the support structure 1a in the longitudinal direction DLO for establishing the tilting position of the idler roller Ri that is enabling correct alignment of the conveyor belt B. The first side structure 2a is used for adjusting a tilt angle a of the idler roller Ri independently of the second side structure 2a, and independently of the position of the support structure 1a relative to the conveyor frame F. The second side structure 2b is used for adjusting the tilt angle a of the idler roller Ri independently of the second side structure 2a, and independently of the position of the support structure 1a relative to the conveyor frame F. In this way, the support structure 1a could be arranged in any position relative to the conveyor frame when adjusting the alignment of the conveyor belt B with the belt tracking unit 2. The belt alignment position of the conveyor belt B may be determined manually by an operator of the conveyor C, or alternatively by suitable sensors arranged within or in connection to the conveyor C. In the shown embodiment, the tilt angle a is defined as the angle between the lateral direction DLA and the direction of the rotational axis of the idler roller Ri, as indicated in figures 4b-c.The first displacement mechanism 3a of the belt tracking unit 2 is arranged between the support structure 1a and the first side structure 2a, as shown in figure 4a. The first displacement mechanism 3a is displacing the first side structure 2a in the longitudinal direction DLO relative to the support structure 1a, as understood from figure 4b. In the shown embodiment, the first displacement mechanism 3a comprises a first bevel gear set 4a attached to the support structure 1a.

[0054] The first bevel gear set 4a comprises a first gear4ai and a second gear4a2, as shown in figures 4a-c. The first gear 4ai and the second gear 4a2 are configured as cone shaped gears that transmit motion between two shafts having intersecting extensions. The first gear4ai is rotatably attached to a longitudinally extending side structure of the support structure 1a, and the first gear 4ai is arranged to rotate around an axis extending in the lateral direction DLA. The second gear 4a2 is rotatably attached to a laterally extending bracket of the support structure 1a, and the second gear 4a2 is arranged to rotate around an axis extending in the longitudinal direction DLO.

[0055] The first bevel gear set 4a is connected to a first threaded coupling 5a, as shown in figures 4a-c. The first threaded coupling 5a is suitably arranged with rubber bushings for a flexible threaded coupling arrangement. The second gear 4a2 of the first bevel gear set 4a is drivingly connected to the first threaded coupling 5a. The first threaded coupling 5a is extending between the support structure 1a and the first side structure 2a, and the first threaded coupling 5a is in threaded engagement with the first side structure 2a. The second gear 4a2 is transferring a rotational movement to a threaded shaft 5as of the first threaded coupling 5a, and the threaded shaft 5as is in threaded engagement with a nut 5aN attached to the first side structure 2a. The rotational movement of the second gear 4a2 is established by rotating the first gear 4ai, e.g. via a suitable tool or other actuating means. When a rotational movement is transferred to the threaded shaft 5as from the second gear 4a2, the first side structure 2a is displaced in the longitudinal direction DLO through the threaded engagement between the threaded shaft 5as and the nut 5aN. Instead of a nut, other internally threaded structures of the first side structure 2a may be used for threaded engagement with the threaded shaft 5as. Thus, upon a rotational displacement of the first bevel gear set 4a, the first threaded coupling 5a is rotated for displacing the first side structure 2a in the longitudinal direction DLO relative to the support structure 1a. By rotating the first gear 4ai in opposite directions, the first side structure 2a can be displaced in thelongitudinal direction DLO both away from and towards the support structure 1a for an efficient alignment of the conveyor belt B.

[0056] The second displacement mechanism 3b of the belt tracking unit 2 is arranged between the support structure 1a and the second side structure 2b, as shown in figure 4a. The second displacement mechanism 3b is displacing the second side structure 2b in the longitudinal direction DLO relative to the support structure 1a, as understood from figure 4c. In the shown embodiment, the second displacement mechanism 3b comprises a second bevel gear set 4b attached to the support structure 1a.

[0057] The second bevel gear set 4b comprises a first gear 4bi and a second gear 4b2, as shown in figures 4a-c. The first gear 4bi and the second gear 4b2 are configured as cone shaped gears that transmit motion between two shafts having intersecting extensions. The first gear4bi is rotatably attached to a longitudinally extending side structure of the support structure 1a, and the first gear 4bi is arranged to rotate around an axis extending in the lateral direction DLA. The second gear 4b2 is rotatably attached to a laterally extending bracket of the support structure 1a, and the second gear 4b2 is arranged to rotate around an axis extending in the longitudinal direction DLO.

[0058] The second bevel gear set 4b is connected to a second threaded coupling 5b, as shown in figures 4a-c. The second threaded coupling 5b is suitably arranged with rubber bushings for a flexible threaded coupling arrangement. The second gear 4b2 of the second bevel gear set 4b is drivingly connected to the second threaded coupling 5b. The second threaded coupling 5b is extending between the support structure 1a and the second side structure 2b, and the second threaded coupling 5b is in threaded engagement with the second side structure 2b. The second gear 4b2 is transferring a rotational movement to a threaded shaft 5bs of the second threaded coupling 5b, and the threaded shaft 5bs is in threaded engagement with a nut 5bN attached to the second side structure 2b. The rotational movement of the second gear 4b2 is established by rotating the first gear 4bi, e.g. via a suitable tool or other actuating means. When a rotational movement is transferred to the threaded shaft 5bs from the second gear4b2, the second side structure 2b is displaced in the longitudinal direction DLO through the threaded engagement between the threaded shaft 5bs and the nut 5bN. Instead of a nut, other internally threaded structures of the second side structure 2b may be used for threaded engagement with the threaded shaft 5bs. Thus, upon arotational displacement of the second bevel gear set 4b, the second threaded coupling 5b is rotated for displacing the second side structure 2b in the longitudinal direction DLO relative to the support structure 1a. By rotating the first gear 4bi in opposite directions, the second side structure 2b can be displaced in the longitudinal direction DLO both away from and towards the support structure 1a for an efficient alignment of the conveyor belt B.

[0059] The belt tracking unit 2 may further comprise one or more actuating devices that are drivingly connected to the first bevel gear set 4a and the second bevel gear set 4b respectively. The one or more actuating devices are used for rotatably displacing the first bevel gear set 4a and the second bevel gear set 4b, for an efficient adjustment of the belt alignment AB.

[0060] In the embodiment shown in figures 4a-c, the belt tracking unit 2 comprises a first actuating device A1 that is configured for being drivingly connected to the first bevel gear set 4a, and a second actuating device A2 that is configured for being drivingly connected to the second bevel gear set 4b. The first actuating device A1 is used for rotatably displacing the first bevel gear set 4a and the second actuating device A2 for rotatably displacing the second bevel gear set 4b. The first actuating device A1 may be arranged as a manually operated actuating mechanism connected to the first bevel gear set 4a, such as an Allen wrench or similar tool that is temporarily brought in engagement with the first gear 4ai of the first bevel gear set 4a. The second actuating device A2 may be arranged as a manually operated actuating mechanism connected to the second bevel gear set 4b, such as an Allen wrench or similar tool that is temporarily brought in engagement with the first gear 4bi of the second bevel gear set 4b. In other embodiments, the first actuating device A1 and the second actuating device A2 may instead be arranged as levers or hand wheels attached to the first bevel gear set 4a and the second bevel gear set 4b respectively. The first gear 4ai of the first bevel gear set 4a is suitably arranged with a hexagonal recess for the Allen key, or similar arrangement for other suitable tools. The first gear 4bi of the second bevel gear set 4b is suitably arranged with a hexagonal recess for the Allen key, or similar arrangement for other suitable tools. In other embodiments, the first actuating device A1 and the second actuating device A2 may instead be arranged as levers or a hand wheels attached to the respective gears.In an alternative embodiment of the conveyor belt controlling system S shown in figure 5, the belt tensioning unit 1 comprises an actuator A that is drivingly connected to the belt tensioner shaft 1b. The actuator A is in this embodiment arranged as an electric actuator drivingly connected to the belt tensioner shaft 1b. The adjustment of the belt tension level LBT of the conveyor belt B is achieved by the electric actuator in the way described above in connection to figures 3a-c. The belt tensioner shaft 1b is with this configuration arranged to rotate through actuation from the electric actuator. The actuator A is suitably an electric motor, where a drive shaft of the electric motor is directly connected or indirectly connected to the belt tensioner shaft 1b. A gear unit or similar arrangement may be arranged between the belt tensioner shaft 1b and the actuator A if desired. Further, the belt tensioning unit 1 may be arranged with a belt tension sensor SBT configured for detecting a belt tension level LBT of the conveyor belt B, and a belt tension control unit UBT connected to the belt tension sensor SBT and the actuator A, as schematically shown in figure 5. The belt tension control unit UBT may be arranged to control the belt tension level LBT based on input from the belt tension sensor SBT, and the belt tension control unit UBT is then adjusting the belt tension level LBT by means of the actuator A based on the detected belt tension level LBT by the belt tension sensor SBT. The belt tension sensor SBT may be any suitable sensor that is detecting the belt tension level LBT in the conveyor belt B. Suitable sensors are for example pressure sensors, load cell sensors, optical sensors, or inductive sensors. Thus, the belt tension level LBT is controlled by the belt tension control unit UBT based on input from the belt tension sensor SBT, and the belt tension control unit UBT is adjusting the belt tension level LBT by means of the actuator A based on the detected belt tension level LBT by the belt tension sensor SBT.

[0061] In other non-illustrated embodiments, the actuator A configured as an electric actuator may instead be manually operated via a switch or similar operating device.

[0062] In the alternative embodiment of the conveyor belt controlling system S shown in figure 5, the belt tracking unit 2 further comprises a first actuating device A1 drivingly connected to the first bevel gear set 4a and a second actuating device A2 drivingly connected to the second bevel gear set 4b. The first actuating device A1 is used for rotatably displacing the first gear 4ai of the first bevel gear set 4a, and the second actuating device A2 is used for rotatably displacing the first gear 4bi of the second bevel gear set 4b. The first actuating device A1 may be arranged as an electricactuator drivingly connected to the first bevel gear set 4a, and the second actuating device A2 may be arranged as an electric actuator drivingly connected to the second bevel gear set 4b. The adjustment of the belt alignment AB of the conveyor belt B is achieved by means of the first actuating device A1 and the second actuating device A2 respectively, in the same way as described above in connection to figures 4a-c. When adjusting the belt alignment AB of the conveyor belt B, the first bevel gear set 4a is rotatably displaced by the first actuating device A1 , and / or the second bevel gear set 4b is rotatably displaced by the second actuating device A2.

[0063] With the configuration shown in figure 5, the belt tracking unit 2 may comprise a belt alignment sensor SBA configured for detecting a belt alignment AB of the conveyor belt B, and further a belt alignment control unit UBA connected to the belt alignment sensor SBA, the first actuating device A1, and the second actuating device A2. The belt alignment control unit UBA is controlling the belt alignment AB based on input from the belt alignment sensor SBA, and the belt alignment control unit UBA is adjusting the belt alignment AB by means of the first actuating device A1 and / or the second actuating device A2 based on the detected belt alignment AB by the belt alignment sensor SBA. The belt alignment sensor SBA may for example be arranged as an optical sensor, a mechanical sensor, or an inductive sensor.

[0064] In other non-illustrated embodiments, the first actuating device A1 and the second actuating device A2 configured as electric actuators may instead be manually operated via one or more switches or similar operating devices.

[0065] The operation of the exemplified conveyor C with a conveyor belt controlling system S is described above in connection to figures 3a-c and 4a-c. The conveyor belt controlling system S is configured for tension adjustment and alignment of the endless conveyor belt B extending in a longitudinal direction DLO between a drive roller RD and an idler roller Ri. The conveyor belt controlling system S comprises the belt tensioning unit 1 attached to the conveyor frame F and the belt tracking unit 2 attached to the belt tensioning unit 1. The idler roller Ri is attached to the belt tracking unit 2, as understood from the figures. The belt tensioning unit 1 comprises a support structure 1a movably arranged relative to the conveyor frame F in the longitudinal direction DLO. The belt tracking unit 2 comprises a first side structure 2a and a second side structure 2b, and the idler roller Ri is arranged between the first side structure 2a and the second side structure 2b.The belt tension level LBT of the conveyor belt B is adjusted by establishing a longitudinal movement of the idler roller Ri through displacement of the support structure 1a relative to the conveyor frame F in the longitudinal direction DLO, as described above in connection to figures 3a-c. In figure 3a, a position of the belt tensioning unit 1 suitable for removing and installing a conveyor belt B is schematically shown. When the conveyor belt has been thoroughly installed, the tension of the conveyor belt B is increased to a suitable level for operating the conveyor C by displacing the support structure 1a away from the conveyor frame F, as shown in figure 3b. In this position, the conveyor C could be operated, and the tension of the conveyor belt B may be further adjusted if needed, by increasing or decreasing the tension, as described above in connection to figure 3c. The tension adjustment is achieved by displacing the support structure 1a in the longitudinal direction DLO relative to the conveyor frame F, and the tensioner rack 1d is transferring a linear movement in the longitudinal direction DLO to the support structure 1a through the rotational displacement of the belt tensioner shaft 1 b with the tensioner pinion 1 c. The belt tensioner shaft 1b is rotatably displaced by the actuator A, as described in the different embodiments above.

[0066] When the conveyor belt B has been installed and the tension has been adjusted correctly, there may be a need to adjust the alignment of the conveyor belt B with the belt tracking unit 2 before operating the conveyor C or during operation of the conveyor C. The conveyor belt B is aligned by establishing a tilting position of the idler roller Ri through individual displacement of the first side structure 2a and / or the second side structure 2b relative to the support structure 1a in the longitudinal direction DLO, as described in connection to figures 4a-c above. It should be understood that after a correct belt alignment AB of the conveyor belt B, there could be a need to further adjust the tension of the conveyor belt by the belt tensioning unit 1. To achieve a correct belt alignment AB, the first side structure 2a is displaced in the longitudinal direction DLO relative to the support structure 1a by the first displacement mechanism 3a, as described above in connection to figure 4b, and / or the second side structure 2b is displaced in the longitudinal direction DLO relative to the support structure 1a by the second displacement mechanism 3b, as described above in connection to figure 4b. The first threaded coupling 5a is rotated through a rotational displacement of the first bevel gear set 4a for displacing the first side structure 2a in the longitudinal direction DLO relative to the support structure 1 a. The second threadedcoupling 5b is rotated through a rotational displacement of the second bevel gear set 4b for displacing the second side structure 2b in the longitudinal direction DLO relative to the support structure 1a. The rotational movements of the respective threaded couplings are efficiently displacing the side structures for a correct belt alignment AB of the conveyor belt B.

[0067] The control units described above in connection to figure 5 are suitably computerized, including one or more processors. The steps, services and functions explained may be implemented using individual hardware circuitry, using software functioning in conjunction with a programmed microprocessor or general purpose computer, using one or more Application Specific Integrated Circuits (ASICs) and / or using one or more Digital Signal Processors (DSPs). It will also be appreciated that when the present disclosure is described in terms of a method, it may also be embodied in one or more processors and one or more memories coupled to the one or more processors, wherein the one or more memories store one or more programs that perform the steps, services and functions disclosed herein when executed by the one or more processors. Different method steps than those described above, performing the method by hardware or software, may be provided within the scope of the disclosure. Thus, according to an exemplary embodiment, there is provided a non-transitory computer-readable storage medium storing one or more programs configured to be executed by one or more processors of the conveyor belt controlling system, the one or more programs comprising instructions for performing the method according to any one of the above-discussed embodiments. Alternatively, according to another exemplary embodiment a cloud computing system can be configured to perform any of the method aspects presented herein. The cloud computing system may comprise distributed cloud computing resources that jointly perform the method aspects presented herein under control of one or more computer program products. Moreover, the processor may be connected to one or more communication interfaces and / or sensor interfaces for receiving and / transmitting data with external entities, an off-site server, or a cloud-based server.

[0068] The processors associated with the control units may be or include any number of hardware components for conducting data or signal processing or for executing computer code stored in memory. The system may have an associated memory, and the memory may be one or more devices for storing data and / or computer code forcompleting or facilitating the various methods described in the present description. The memory may include volatile memory or non-volatile memory. The memory may include database components, object code components, script components, or any other type of information structure for supporting the various activities of the present description. According to an exemplary embodiment, any distributed or local memory device may be utilized with the systems and methods of this description. According to an exemplary embodiment the memory is communicably connected to the processor (e.g., via a circuit or any other wired, wireless, or network connection) and includes computer code for executing one or more processes described herein.

[0069] It will be appreciated that the above description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art that various changes may be made without departing from the scope of the present disclosure as defined in the claims. Furthermore, modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within the appended claims. Reference signs mentioned in the claims should not be seen as limiting the extent of the matter protected by the claims, and their sole function is to make claims easier to understand.REFERENCE SIGNS

[0070] 1: Belt tensioning unit

[0071] 1a: Support structure

[0072] 1 b: Belt tensioner shaft

[0073] 1c: Tensioner pinion

[0074] 1d: Tensioner rack

[0075] 2: Belt tracking unit

[0076] 2a: First side structure

[0077] 2b: Second side structure

[0078] 3a: First displacement mechanism 3b: Second displacement mechanism 4a: First bevel gear set

[0079] 4ai: First gear

[0080] 4a2: Second gear

[0081] 4b: Second bevel gear set

[0082] 4bi: First gear

[0083] 4b2: Second gear

[0084] 5a: First threaded coupling

[0085] 53N: Nut

[0086] 5as: Threaded shaft

[0087] 5b: Second threaded coupling 5bN: Nut

[0088] 5bs: Threaded shaft

[0089] a: Tilt angle

[0090] A: Actuator

[0091] AB: Belt alignment

[0092] A1 : First actuating device

[0093] A2: Second actuating device

[0094] B: Conveyor belt

[0095] C: Conveyor

[0096] DLA: Lateral direction

[0097] DLO: Longitudinal direction

[0098] F: Conveyor frameLBT: Belt tension level

[0099] RD: Drive roller

[0100] Ri: Idler roller

[0101] S: Conveyor belt controlling system SBA: Belt alignment sensor

[0102] SBT: Belt tension sensor

[0103] UBA: Belt alignment control unit UBT: Belt tension control unit

Claims

28CLAIMS1. A conveyor belt controlling system (S) configured for tension adjustment and alignment of an endless conveyor belt (B) extending in a longitudinal direction (DLO) between a drive roller (RD) and an idler roller (Ri),wherein the conveyor belt controlling system (S) comprises a belt tensioning unit (1) attached to a conveyor frame (F) and a belt tracking unit (2) attached to the belt tensioning unit (1), wherein the idler roller (Ri) is attached to the belt tracking unit (2),wherein the belt tensioning unit (1) comprises a support structure (1a) movably arranged relative to the conveyor frame (F) in the longitudinal direction (DLO) for establishing a longitudinal movement of the idler roller (Ri) enabling tension adjustment of the conveyor belt (B),wherein the belt tracking unit (2) comprises a first side structure (2a) and a second side structure (2b), wherein the idler roller (Ri) is arranged between the first side structure (2a) and the second side structure (2b), wherein each of the first side structure (2a) and the second side structure (2b) is individually movable relative to the support structure (1a) in the longitudinal direction (DLO) for establishing a tilting position of the idler roller (Ri) enabling alignment of the conveyor belt (B).

2. The conveyor belt controlling system (S) according to claim 1,wherein the belt tensioning unit (1) comprises a belt tensioner shaft (1 b) with a tensioner pinion (1c) rotatably connected to the conveyor frame (F) and a toothed tensioner rack (1d) attached to the support structure (1a), wherein the tensioner pinion (1c) is in threaded engagement with the tensioner rack (1 d), wherein upon a rotational displacement of the belt tensioner shaft (1b) with the tensioner pinion (1c), the tensioner rack (1 d) is configured for displacing the support structure (1a) in the longitudinal direction (DLO) relative to the conveyor frame (F).

3. The conveyor belt controlling system (S) according to claim 2,wherein the tensioner rack (1 d) is extending in the longitudinal direction (DLO) and the belt tensioner shaft (1b) is extending in a lateral direction (DLA).

4. The conveyor belt controlling system (S) according to claim 2 or 3, wherein the belt tensioning unit (1) comprises an actuator (A) drivingly connected to the belt tensioner shaft (1b), wherein the actuator (A) is configured for rotatably displacing the belt tensioner shaft (1b).

5. The conveyor belt controlling system (S) according to claim 4,wherein the actuator (A) is a manually operated actuating mechanism connected to the belt tensioner shaft (1b).

6. The conveyor belt controlling system (S) according to claim 4,wherein the actuator (A) is arranged as an electric actuator drivingly connected to the belt tensioner shaft (1b), wherein the belt tensioning unit (1) comprises a belt tension sensor (SBT) configured for detecting a belt tension level (LBT) of the conveyor belt (B) and a belt tension control unit (UBT) connected to the belt tension sensor (SBT) and the actuator (A), wherein the belt tension control unit (UBT) is configured for controlling the belt tension level (LBT) based on input from the belt tension sensor (SBT), wherein the belt tension control unit (UBT) is configured for adjusting the belt tension level (LBT) by means of the actuator (A) based on the detected belt tension level (LBT) by the belt tension sensor (SBT).

7. The conveyor belt controlling system (S) according to any preceding claim, wherein the belt tracking unit (2) comprises a first displacement mechanism (3a) arranged between the support structure (1a) and the first side structure (2a), wherein the first displacement mechanism (3a) is configured for displacing the first side structure (2a) in the longitudinal direction (DLO) relative to the support structure (1a),wherein the belt tracking unit (2) comprises a second displacement mechanism (3b) arranged between the support structure (1a) and the second side structure (2b), wherein the second displacement mechanism (3b) is configured for displacing the second side structure (2b) in the longitudinal direction (DLO) relative to the support structure (1a).

8. The conveyor belt controlling system (S) according to claim 7,wherein the first displacement mechanism (3a) comprises a first bevel gear set (4a) attached to the support structure (1a), wherein the first bevel gear set (4a) is connected to a first threaded coupling (5a) extending between the support structure (1a) and the first side structure (2a), wherein the first threaded coupling (5a) is in threaded engagement with the first side structure (2a), wherein upon a rotational displacement of the first bevel gear set (4a) the first threaded coupling (5a) is rotated for displacing the first side structure (2a) in the longitudinal direction (DLO) relative to the support structure (1a),wherein the second displacement mechanism (3b) comprises a second bevel gear set (4b) attached to the support structure (1a), wherein the second bevel gear set (4b) is connected to a second threaded coupling (5b) extending between the support structure (1a) and the second side structure (2b), wherein the second threaded coupling (5b) is in threaded engagement with the second side structure (2b), wherein upon a rotational displacement of the second bevel gear set (4b) the second threaded coupling (5b) is rotated for displacing the second side structure (2b) in the longitudinal direction (DLO) relative to the support structure (1a).

9. The conveyor belt controlling system (S) according to claim 8,wherein the belt tracking unit (2) comprises a first actuating device (A1) drivingly connected to the first bevel gear set (4a) and a second actuating device (A2) drivingly connected to the second bevel gear set (4b),wherein the first actuating device (A1) is configured for rotatably displacing the first bevel gear set (4a) and the second actuating device (A2) is configured for rotatably displacing the second bevel gear set (4b).

10. The conveyor belt controlling system (S) according to claim 9,wherein the first actuating device (A1) is a manually operated actuating mechanism connected to the first bevel gear set (4a) and the second actuating device (A2) is a manually operated actuating mechanism connected to the second bevel gear set (4b).

11. The conveyor belt controlling system (S) according to claim 9,wherein the belt tracking unit (2) comprises a belt alignment sensor (SBA) configured for detecting a belt alignment (AB) of the conveyor belt (B), wherein the first actuating device (A1) is arranged as an electric actuator drivingly connected to the first bevel gear set (4a) and the second actuating device (A2) is arranged as an electric actuator drivingly connected to the second bevel gear set (4b),wherein the belt tracking unit (2) comprises a belt alignment control unit (UBA) connected to the belt alignment sensor (SBA), the first actuating device (A1), and the second actuating device (A2),wherein the belt alignment control unit (UBA) is configured for controlling the belt alignment (AB) based on input from the belt alignment sensor (SBA), wherein the belt alignment control unit (UBA) is configured for adjusting the belt alignment (AB) by means of the first actuating device (A1) and / or the second actuating device (A2) based on the detected belt alignment (AB) by the belt alignment sensor (SBA).

12. A method for controlling a conveyor belt controlling system (S) configured for tension adjustment and alignment of an endless conveyor belt (B) extending in a longitudinal direction (DLO) between a drive roller (RD) and an idler roller (Ri), wherein the conveyor belt controlling system (S) comprises a belt tensioning unit (1) attached to a conveyor frame (F) and a belt tracking unit (2) attached to the belt tensioning unit (1), wherein the idler roller (Ri) is attached to the belt tracking unit (2),wherein the belt tensioning unit (1) comprises a support structure (1a) movably arranged relative to the conveyor frame (F) in the longitudinal direction (DLO), wherein the belt tracking unit (2) comprises a first side structure (2a) and a second side structure (2b), wherein the idler roller (Ri) is arranged between the first side structure (2a) and the second side structure (2b), wherein the method comprises the steps:adjusting the tension of the conveyor belt (B) by establishing a longitudinal movement of the idler roller (Ri) through displacement of the support structure (1a) relative to the conveyor frame (F) in the longitudinal direction (DLO);and / or aligning the conveyor belt (B) by establishing a tilting position of the idler roller (Ri) through individual displacement of the first side structure (2a)32and / or the second side structure (2b) relative to the support structure (1a) in the longitudinal direction (DLO).

13. The method according to claim 12,wherein the belt tensioning unit (1) comprises a belt tensioner shaft (1 b) with a tensioner pinion (1c) rotatably connected to the conveyor frame (F) and a toothed tensioner rack (1d) attached to the support structure (1a), wherein the tensioner pinion (1c) is in threaded engagement with the tensioner rack (1 d), wherein the method further comprises the step: displacing the support structure (la) in the longitudinal direction (DLO) relative to the conveyor frame (F) by the tensioner rack (1d) through a rotational displacement of the belt tensioner shaft (lb) with the tensioner pinion (1c).

14. The method according to claim 13,wherein the belt tensioning unit (1) comprises an actuator (A) drivingly connected to the belt tensioner shaft (1b), wherein the method further comprises the step: rotatably displacing the belt tensioner shaft (1b) by the actuator (A).

15. The method according to claim 14,wherein the actuator (A) is arranged as an electric actuator drivingly connected to the belt tensioner shaft (1b), wherein the belt tensioning unit (1) comprises a belt tension sensor (SBT) configured for detecting a belt tension level (LBT) of the conveyor belt (B) and a belt tension control unit (UBT) connected to the belt tension sensor (SBT) and the actuator (A), wherein the method further comprises the step: controlling the belt tension level (LBT) by the belt tension control unit (UBT) based on input from the belt tension sensor (SBT), wherein the belt tension control unit (UBT) is adjusting the belt tension level (LBT) by means of the actuator (A) based on the detected belt tension level (LBT) by the belt tension sensor (SBT).

16. The method according to any of claims 12 to 15,wherein the belt tracking unit (2) comprises a first displacement mechanism (3a) arranged between the support structure (1a) and the first side structure (2a), and a second displacement mechanism (3b) arranged between33the support structure (1a) and the second side structure (2b), wherein the method further comprises the steps: displacing the first side structure (2a) in the longitudinal direction (DLO) relative to the support structure (1a) by the first displacement mechanism (3a); and / or displacing the second side structure (2b) in the longitudinal direction (DLO) relative to the support structure (1a) by the second displacement mechanism (3b).

17. The method according to claim 16,wherein the first displacement mechanism (3a) comprises a first bevel gear set (4a) attached to the support structure (1a), wherein the first bevel gear set (4a) is connected to a first threaded coupling (5a) extending between the support structure (1a) and the first side structure (2a), wherein the first threaded coupling (5a) is in threaded engagement with the first side structure (2a),wherein the second displacement mechanism (3b) comprises a second bevel gear set (4b) attached to the support structure (1a), wherein the second bevel gear set (4b) is connected to a second threaded coupling (5b) extending between the support structure (1a) and the second side structure (2b), wherein the second threaded coupling (5b) is in threaded engagement with the second side structure (2b), wherein the method further comprises the steps:rotating the first threaded coupling (5a) through a rotational displacement of the first bevel gear set (4a) for displacing the first side structure (2a) in the longitudinal direction (DLO) relative to the support structure (1a); and / or rotating the second threaded coupling (5b) through a rotational displacement of the second bevel gear set (4b) for displacing the second side structure (2b) in the longitudinal direction (DLO) relative to the support structure (1a).

18. The method according to claim 17,wherein the belt tracking unit (2) comprises a first actuating device (A1) drivingly connected to the first bevel gear set (4a) and a second actuating device (A2) drivingly connected to the second bevel gear set (4b), wherein the method further comprises the steps:rotatably displacing the first bevel gear set (4a) by the first actuating device (A1); and / or rotatably displacing the second bevel gear set (4b) by the second actuating device (A2).3419. The method according to claim 18,wherein the belt tracking unit (2) comprises a belt alignment sensor (SBA) configured for detecting a belt alignment (AB) of the conveyor belt (B), wherein the first actuating device (A1) is arranged as an electric actuator drivingly connected to the first bevel gear set (4a) and the second actuating device (A2) is arranged as an electric actuator drivingly connected to the second bevel gear set (4b),wherein the belt tracking unit (2) comprises a belt alignment control unit (UBA) connected to the belt alignment sensor (SBA), the first actuating device (A1), and the second actuating device (A2), wherein the method further comprises the steps:controlling the belt alignment (AB) by the belt alignment control unit (UBA) based on input from the belt alignment sensor (SBA), wherein the belt alignment control unit (UBA) is adjusting the belt alignment (AB) by means of the first actuating device (A1) and / or the second actuating device (A2) based on the detected belt alignment (AB) by the belt alignment sensor (SBA).

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