Chain Tension Sensor with Reaction Arm and Load Pin
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Solution Overview
Problem
Conventional longwall conveyors face challenges in maintaining optimal chain tension due to changing load conditions and frequent repositioning, leading to potential chain breakages and increased downtime, as well as difficulties in detecting broken chains and adjusting conveyor positions to prevent face creep.
Innovation Solution
A tension sensing system using reaction arms and load sensing pins to detect chain tension and identify broken chains, coupled with telescopic frames for independent adjustment of conveyor ends to maintain optimal tension and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual identification of broken chain is attempted, then broken chains can be detected, but operators cannot safely access the return end due to safety requirements
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system. A camera positioned at the discharge end captures images of the chain, and image processing algorithms automatically identify broken chains by analyzing link spacing and geometry, eliminating the need for operator proximity to the hazardous return end
Solution Approach 2:
The patent introduces an intermediary detection system consisting of a camera and image processing software that acts as a mediator between the broken chain and the operator. The system captures visual information from a safe distance and processes it to provide broken chain detection without requiring operator exposure to safety hazards
2Stability of the object's composition
If pre-tension is applied to control chain slack, then chain extension is reduced, but chain tension varies with load changes and repositioning
Solution Approach 1:
The patent transitions from static pre-tensioning to dynamic tension adjustment. Telescopic end frames with actuators continuously adjust the conveyor length in real-time based on feedback from tension sensors, allowing the system to adapt to varying loads and maintain optimal chain tension throughout operation
Solution Approach 2:
The patent implements a closed-loop control system where tension sensors monitor chain tension continuously, and this feedback is used by control algorithms to adjust the telescopic end frame position, maintaining optimal tension despite load variations and repositioning activities
3Stability of the object's composition
If operators manually adjust conveyor position to counteract face creep, then alignment can be maintained, but the process is slow and requires considerable skill
Solution Approach 1:
The patent replaces manual operator adjustment with automated positioning systems. Sensors detect conveyor misalignment and face creep, and automated actuators adjust the conveyor end frame position to maintain alignment, eliminating the need for skilled manual intervention and significantly increasing adjustment speed
Solution Approach 2:
The patent enables the conveyor system to self-correct alignment issues through automated detection and adjustment mechanisms. The system monitors its own position and automatically compensates for face creep and misalignment without requiring external operator intervention
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
The system reliably detects chain tension and broken chains, preventing further damage and allowing for quick adjustments to maintain chain tension and alignment, reducing downtime and improving operational efficiency.
Implementation Method 1
The load sensing pin is positioned to extend through the reaction arm and the conveyor frame and senses a shear force
Implementation Method 2
The reaction arm has a first end that is pivotably coupled to a conveyor frame by a hinge pin
Data Source
AI summary
A chain tension sensor for a chain conveyor, the conveyor including a frame and a chain having a plurality of flights. The tension sensor includes a reaction arm and a load sensing pin. The reaction arm includes a first end, a second end opposite the first end, and a load pad. The first end is pivotably coupled to the frame by a pivot pin defining a pivot axis. The load pad is adjacent the conveyor chain and positioned to contact flights passing the load pad. The flights contacting the load pad exert a force on the reaction in a direction that is perpendicular to the pivot axis. The load sensing pin is coupled to the reaction arm such that the load sensing pin senses the force that is exerted by the flights.