Belt Conveyor Sensor Apparatus for Idler Roller Condition Monitoring
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Solution Overview
Problem
The existing infrastructure for monitoring idler rollers in conveyor systems is complex and costly, with challenges in reliable data transmission due to material properties and contamination, requiring extensive re-equipment and infrastructure for intelligent idlers, which is economically and technically inhibitive.
Innovation Solution
A sensor device integrated into the conveyor belt with a first and second sensor rotated by 180°, arranged with a thickening of elastically deformable material, capable of detecting shear stresses and force variations, along with a 2-dimensional sensor system for measuring forces and pressures, and an energy harvesting unit with a peristaltic pump for self-sufficient energy supply, allowing for the detection of support roller conditions without extensive re-equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If intelligent idlers with measurement and transmission technology are equipped, then support roller condition detection is improved, but device complexity and infrastructure requirements increase significantly
Solution Approach 1:
Instead of equipping support rollers with sensors and transmission technology, the patent inverts the approach by installing sensors directly in the conveyor belt. The belt-mounted sensors detect support roller conditions as the belt passes over them, eliminating the need for complex infrastructure along the conveyor lines while maintaining detection capability.
Solution Approach 2:
The conveyor belt itself serves as an intermediary carrier for the sensor system. By integrating sensors into the belt, the system uses the existing belt infrastructure to transport measurement data from support rollers to a central evaluation system, avoiding the need for separate transmission infrastructure.
2Loss of information
If wireless transmission between support rollers is implemented, then data transmission is improved, but reliability deteriorates due to material properties and contamination
Solution Approach 1:
The patent replaces wireless transmission with a mechanical data transmission system. Sensors mounted in the conveyor belt physically contact support rollers to detect conditions, and data is transmitted through the belt's mechanical structure to a stationary receiver, eliminating wireless transmission vulnerabilities to contamination and material properties.
3Device complexity
If sensors are arranged in the conveyor belt to detect support roller conditions, then infrastructure complexity is reduced, but measurement precision may be affected by force isolation requirements
Solution Approach 1:
The sensor system is segmented into multiple independent sensor units distributed along the conveyor belt. Each sensor unit independently detects forces from individual support rollers, allowing precise measurement of localized conditions while the overall system remains simplified and integrated into the belt structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the infrastructure required for idler roller monitoring by enabling reliable detection of support roller conditions, including stiffness, foreign body ingress, and misalignment, while providing a self-sufficient energy supply, reducing costs and maintenance, and ensuring continuous operation.
Implementation Method 1
a thickened portion made of elastically deformable material, preferably rubber-elastic belt material, is arranged between the two sensors. This allows shear stresses to be detected in a simple manner
Implementation Method 2
an energy harvesting unit with a peristaltic pump for self-sufficient energy supply
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a belt conveyor and to a sensor apparatus (47) for a belt conveyor for detecting an operating state of load-bearing rollers (7) of the belt conveyor. The invention further relates to a method for operating a sensor apparatus (47) embedded in the belt (9) for detecting a functional state of the load-bearing rollers (7), wherein a thickened portion (64) is arranged between two sensors (167, 267). In order to reduce a vertical force, a contraction stop (69) is preferably provided in the thickened portion (64).