Conveyor Slip Detection Using Torque Limiting Device Sensors
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Solution Overview
Problem
Conveyor systems in longwall mining, such as armored face conveyors and beam stage loaders, face issues with excessive torque leading to potential chain failures due to sudden impacts, which existing torque limiting devices do not adequately address by effectively detecting and controlling slip.
Innovation Solution
Incorporating a torque limiting device with a controller that uses sensors to detect the slip between its portions and generate control signals to manage conveyor operation, preventing damage by identifying and responding to excessive torque conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque limiting device is used to prevent excessive torque, then chain failures are reduced, but slip detection and control capability is insufficient
Solution Approach 1:
The patent implements feedback by using sensors to continuously monitor the position of the first and second portions of the torque limiting device, calculating slip amount, and generating control signals based on detected slip conditions. This closed-loop feedback system enables real-time detection and response to slip events, transforming the passive torque limiting device into an actively monitored and controlled system that precisely detects slip while maintaining reliability.
2Measurement precision
If sensors and control systems are added to detect slip, then slip detection precision is improved, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives sensor signals, determines position values, calculates slip amounts, generates control signals, and manages conveyor operation. By making the controller a multi-functional component rather than adding separate dedicated devices for each function, the system achieves precise slip detection while minimizing the increase in overall device complexity.
Solution Approach 2:
The patent combines the slip detection functionality with the existing torque limiting device structure. The sensors are integrated to monitor the relative position between the first and second portions, and the control system is merged with the drive mechanism control, allowing slip detection and control to be implemented within the existing system framework rather than as a completely separate complex subsystem.
3Strength
If the torque limiting device allows slip to occur, then excessive torque is prevented, but conveyor operation continuity is compromised
Solution Approach 1:
The system performs preliminary action by detecting slip conditions before they lead to chain failure or excessive torque damage. The sensors continuously monitor the torque limiting device portions, and the controller calculates slip amounts in advance, generating control signals to adjust drive mechanism operation proactively. This preliminary detection and response prevents the need for complete conveyor shutdowns, maintaining operation continuity while providing torque protection.
Solution Approach 2:
The feedback mechanism enables real-time monitoring of slip conditions and automatic control responses. When slip is detected, the controller generates control signals to adjust the drive mechanism, preventing excessive torque while maintaining conveyor operation. This continuous feedback loop allows the system to respond dynamically to torque conditions, protecting against damage while minimizing interruptions to productivity.
Data Source
AI summary
Conveyor slip detection and control. A controller is operable to receive a first signal from a first sensor, determine a first value for a position of a first portion of a torque limiting device based on the first signal, receive a second signal from a second sensor, determine a second value for a position of a second portion of the torque limiting device based on the second signal, determine a difference between the first value for the position of the first portion and the second value for the position of the second portion, determine an amount of slip between the first portion and the second portion based on the difference, and generate a control signal to control an operation of the conveyor based on the amount of slip.