Conveyor Tension Control via Trajectory Estimation

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Solution Overview

Problem

Conveyor systems in mining operations, such as armored face conveyors and beam stage loaders, face challenges in maintaining optimal tension, leading to inefficient material transport, increased wear, and potential malfunctions due to improper tensioning.

Innovation Solution

A conveyor system incorporating a sprocket, conveyor element, sensor, and electronic processor that estimates the conveyor element's trajectory and determines slack distance, enabling precise control of the tensioning system to maintain an adequate tension range, using sensors like analog output sensors and proximity sensors to generate output signals for tension correction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional tensioning methods are used without precise measurement, then the system is simpler and easier to operate, but the conveyor tension cannot be maintained within optimal range leading to increased wear and potential malfunctions

Engineering Contradiction:

Improveconveyor tension maintenanceVSAvoidtensioning system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical tension measurement methods with an optical sensing system. A sensor positioned adjacent to the sprocket detects the trajectory of the conveyor element, and an electronic processor calculates slack distance based on the detected trajectory, eliminating the need for complex mechanical tension sensors while achieving precise tension control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary computational approach where the electronic processor acts as a mediator between the simple optical sensor and the tensioning system. The processor receives sensor output signals, estimates conveyor element trajectory, determines slack distance values, and converts these into tension correction commands, bridging the gap between simple detection and precise control

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If manual tension adjustment is used, then the system is easier to operate, but material transport efficiency decreases and wear increases due to improper tensioning

Engineering Contradiction:

Improvematerial transport efficiencyVSAvoidtension adjustment operation

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent implements a closed-loop feedback system where the sensor continuously monitors conveyor element position, the electronic processor calculates real-time slack distance, and the tensioning system automatically adjusts tension based on these calculations. This feedback mechanism maintains optimal tension dynamically, maximizing material transport efficiency without requiring manual intervention

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The tensioning system performs self-adjustment based on sensor input and processor calculations. The system automatically detects tension deviations through trajectory monitoring and corrects them without operator intervention, making the complex tension control process transparent and easy to operate while maintaining high productivity

Inventive Principle:

Principle #25Self-service

3Measurement precision

If precise trajectory estimation and slack distance calculation are implemented, then tension control precision is improved, but the device complexity and measurement requirements increase

Engineering Contradiction:

Improveslack distance measurementVSAvoidsensor and processor complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical measurement devices with an optical sensor that detects conveyor element trajectory. The sensor generates output signals that the electronic processor uses to calculate slack distance through trajectory estimation, achieving high measurement precision with simpler optical components rather than complex mechanical gauges

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electronic processor serves as an intermediary that transforms simple sensor output signals into precise slack distance measurements. By estimating trajectory from basic position data and computing slack distance mathematically, the processor achieves high measurement precision without requiring complex sensor hardware

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11511943B2Sensor systems and methods for detecting conveyor tension in a mining system

Publication Date: 2022.11.29 JOY GLOBAL UNDERGROUND MINING LLC

AI summary

A conveyor system that includes a sprocket, a conveyor element, a sensor, a tensioning system, and an electronic processor. The conveyor element is coupled to the sprocket to move around the sprocket. The sensor is positioned adjacent to the sprocket and configured to generate an output signal indicative of a detection of the conveyor element. The electronic processor is coupled to the sensor and to the tensioning system. The electronic processor is configured to receive the output signal from the sensor, estimate a trajectory of the conveyor element based on the output signal, determine a value for slack distance based on the estimated trajectory of the conveyor element, and control the tensioning system based on the value for slack distance.