Conveyor Carriage Position Monitoring via Optical Target
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing position monitoring systems for conveyor belts in the mining industry, such as incremental end coders, are inaccurate and require frequent resets due to power outages, leading to unreliable tension maintenance and operational issues.
Innovation Solution
A carriage system with a winch, position sensor, and controller that calculates system characteristics based on the carriage position, motor rotational speed, and direction, using a cable and motor sensor to maintain accurate conveyor belt tension and detect mechanical issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If incremental end coders are used to monitor conveyor belt position, then the system structure is simple, but the measurement accuracy is poor and the system requires frequent resets due to power outages
Solution Approach 1:
The patent replaces the mechanical incremental encoder system with an optical measurement system. The optical sensor detects the position of a target on the conveyor carriage by measuring the reflected light, eliminating the need for mechanical shaft encoders and their associated mechanical components. This substitution provides continuous, accurate position data without mechanical wear or power dependency.
Solution Approach 2:
The patent introduces a target as an intermediary element attached to the conveyor carriage. This target serves as a passive reflector that mediates between the optical sensor and the carriage position, enabling non-contact measurement. The target simplifies the measurement process while maintaining high accuracy without requiring complex sensor systems.
2Reliability
If incremental end coders are used for position monitoring, then the device complexity is low, but the reliability is poor due to power outage resets
Solution Approach 1:
The patent replaces the power-dependent incremental encoder with an optical measurement system that does not require power for the measurement function itself. The optical sensor and target system can continuously monitor position without power interruptions affecting the measurement, thereby eliminating the reliability issue of resets during power outages.
Solution Approach 2:
The optical target on the conveyor carriage serves itself by passively reflecting light back to the sensor. This self-service mechanism eliminates the need for powered components at the measurement point, allowing the system to maintain reliability during power outages while keeping the overall system relatively simple.
3Reliability
If incremental end coders are used, then the system is easy to operate, but the tension maintenance is unreliable leading to operational issues
Solution Approach 1:
The patent implements continuous feedback by using the optical sensor to constantly monitor the conveyor carriage position and feed this information to the controller. This real-time feedback enables the controller to make continuous adjustments to maintain proper belt tension, eliminating the unreliable intermittent measurements of incremental coders and ensuring consistent operational performance.
Solution Approach 2:
The replacement of incremental encoders with an optical measurement and feedback system provides continuous, reliable position data that enables accurate tension maintenance. This substitution maintains ease of operation through automated control while dramatically improving reliability by eliminating the measurement errors and power dependency of mechanical encoders.
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 provides accurate and continuous position monitoring, enabling reliable conveyor belt tension maintenance and real-time detection of operational issues, such as belt breaks or misalignment, thereby enhancing operational safety and efficiency.
Implementation Method 1
a position sensor configured to sense a position of the target
Implementation Method 2
The motor sensor senses a motor characteristic
Data Source
AI summary
A carriage system including a carriage having a target; a winch; a position sensor configured to sense a position of the target; and a controller. The winch includes a cable, a motor, and a motor sensor. The cable couples the carriage to the winch. The motor sensor senses a motor characteristic. The controller is configured to receive the motor characteristic and the position of the target, calculate a characteristic of the system, and output the characteristic.