Conveyor Belt Tear Detection Using Chain Trigger
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Solution Overview
Problem
Existing conveyor belt monitoring systems in the mining industry face inefficiencies in detecting longitudinal and transverse tears due to high friction losses and delayed detection, and lack weather resistance, with complex and costly alternatives.
Innovation Solution
Replacing steel cables with chains and using inductive load limit switches to minimize friction and enhance reliability and weather resistance, while maintaining high tensile strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel cables are used as triggers, then high tensile strength is achieved, but friction losses with the conveyor belt increase significantly
Solution Approach 1:
The patent extracts the problematic friction interface by replacing the steel cable that directly contacts the conveyor belt with a chain that hangs below the belt without contact. The chain serves as the trigger element but eliminates the harmful friction interaction while maintaining the tensile strength function for tear detection.
2Measurement precision
If steel cables are positioned closer to the conveyor belt for better detection, then detection sensitivity improves, but friction losses increase
Solution Approach 1:
Instead of positioning the trigger element above or in contact with the conveyor belt to improve detection, the patent inverts the arrangement by placing the chain below the belt. The chain detects tears through tension changes transmitted through the belt structure, eliminating friction while maintaining detection capability.
3Device complexity
If mechanical load limit switches are used, then simple construction is achieved, but weather resistance deteriorates
Solution Approach 1:
The patent replaces the mechanical load limit switch with an inductive proximity switch that detects the position of the chain without mechanical contact. This substitution eliminates the weather resistance problems of mechanical switches while maintaining the simple construction principle, as inductive switches have no moving parts that can fail in harsh environments.
4Measurement precision
If complex monitoring devices are used to improve detection capability, then detection accuracy improves, but manufacturing cost increases
Solution Approach 1:
The patent employs standard inductive proximity switches that are mass-produced and readily available at low cost. These switches provide reliable tear detection accuracy without requiring complex custom-designed monitoring devices, thus maintaining ease of manufacture and low manufacturing cost.
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
Enables rapid detection of conveyor belt tears with reduced friction losses and improved weather resistance, achieved through the use of chains and inductive proximity switches, which are cost-effective and reliable.
Implementation Method 1
an inductive load limit switch which according to the invention includes an inductive, safe or unsafe proximity switch
Data Source
AI summary
The invention relates to an arrangement for detecting a belt tear in a conveyor belt, comprising a trigger (1) which is arranged below the conveyor belt (2) transversely to the conveying direction of the conveyor belt and which is connected to a load limit switch (3). The arrangement also comprises a signalling device (4) for indicating and/or signalling a belt tear to a control unit (5). The invention is characterized in that a chain (6) which is suspended below the conveyor belt (2) is used as the trigger (1), said chain transmitting forces produced in the event of a belt tear to the load limit switch (3). In an advantageous embodiment, the load limit switch (3) has an inductive proximity switch (7), and in an additional advantageous embodiment, the load limit switch is connected to a control unit (5) via an actuator sensor interface (8) as a bus participant.