Roller Conveyor Breakage Detection via Resistance Cable
Solution Overview
Problem
Existing systems for detecting roller breakage in continuous roller conveyors, particularly in the ceramics industry, activate alerts only after a material pileup occurs, failing to promptly detect single roller breakages or vertical displacements, leading to inefficient production halts and high energy consumption.
Innovation Solution
A system featuring a tensioned main cable with distributed contact elements and a secondary cable, where the main cable's resistance change upon roller breakage is detected, automatically deactivating the conveyor and identifying the breakage location, reducing energy consumption and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photocell sensors are used to detect material pileup, then the alert is activated when material accumulation is detected, but the alert is activated only after a certain layer of material has built up, causing delay in detecting single roller breakages
Solution Approach 1:
The patent replaces the optical detection system (photocells detecting light beam interruption) with an electrical resistance-based detection system. A conductor wire is tensioned above the roller ends, and when a roller breaks, the idle end touches the wire, creating an electrical contact that immediately triggers the alert. This mechanical-electrical substitution enables direct detection of roller breakage without requiring material accumulation.
Solution Approach 2:
The conductor wire acts as an intermediary element positioned between the roller ends and the detection system. When a roller breaks, the idle end rises and contacts the wire, which then establishes electrical contact with the support structure, triggering the alert. This intermediary mechanism provides direct detection of the breakage event itself, eliminating the time delay associated with material pileup detection.
2Reliability
If a conductor wire system is used for immediate roller breakage detection, then rapid detection of single roller breakages is achieved, but constant electrical potential application and earth connections require high energy consumption
Solution Approach 1:
The patent employs periodic or intermittent electrical potential application rather than constant potential. The conductor wire system is designed so that electrical potential is applied only when needed for detection, or the system uses the natural electrical properties of the materials without requiring continuous power input. This reduces energy consumption while maintaining detection reliability.
Solution Approach 2:
The detection system utilizes the inherent electrical properties of the conductor wire and support structure. The wire itself serves as both the mechanical indicator (positioning itself above the roller ends) and the electrical detection element. When contact occurs, the existing electrical potential in the system (from the support structure or control circuitry) is sufficient to detect the breakage without requiring additional energy input, making the system self-sufficient.
3Loss of information
If visual inspection of the entire roller conveyor is required to locate breakage, then the breakage position can be identified, but the inspection step requires considerable time due to the extension of the conveyor
Solution Approach 1:
The conductor wire system is divided into multiple segments or zones, with the wire passing through or near each roller support position. When a breakage occurs, the system can identify which specific segment or zone experienced the contact, providing localized information about the breakage position. This segmentation eliminates the need for operators to inspect the entire conveyor length visually.
Solution Approach 2:
The detection system provides immediate feedback about the breakage location through the electrical contact point. When the conductor wire contacts the support structure due to a broken roller, the system can determine the position of contact along the wire's length, providing real-time location information. This feedback mechanism allows operators to go directly to the problematic area without time-consuming visual inspection of the entire conveyor.
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 immediate detection and location of roller breakages, minimizing production disruptions and energy use, while being easily installable on new or existing conveyors, and adaptable to various conveyor configurations.
Implementation Method 1
a main cable 2 which in use is positioned tensioned above the second ends 106 of the rollers 103, but not in contact with them
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system (1) for detecting the breakage of rollers of continuous roller conveyors, particularly for kilns and dryers for the ceramics industry. The continuous conveyor (100) is of the type that comprises a structure (101) for supporting at least one conveyance surface (102) which comprises a plurality of rollers (103) that are arranged so that their corresponding longitudinal axes (A) are substantially parallel and juxtaposed along a transfer direction (T) that is substantially transverse to the longitudinal axes (A) of the rollers, each roller (103) having a first end (104) associated with means for rotational actuation (105) about its own longitudinal axis (A) and a second end (106), arranged opposite the first end, which is supported so that it can rotate freely; the system (1) comprises a main cable (2) which is adapted to be arranged in an upper region proximate to, but not in contact with, the idle second ends (106) of the rollers (103) of the at least one conveyance surface (102), and which is made of an electrically conducting material and has a characteristic value (Vc) of electrical resistance per unit of length; the main cable (2) therefore has a maximum value (Vmax) of electric resistance that corresponds to its total length (Ltot); the system (1) further comprises a plurality of contact elements (3) made of electrically conducting material, which are distributed along the main cable (2) and are arranged above it and not in contact with it; following the breakage of a roller (103) the inclination of the corresponding second end (106) is adapted to interfere with the main cable (2) until it is brought into contact with at least one of the contact elements (3); the system (1) further comprises a secondary cable (9) made of electrically conducting material which is electrically connected in series to the plurality of contact elements (3), means for detecting (10) a value (Vr) of electrical resistance referred to the main cable (2), which are electrically connected to the main and secondary cables (2, 9), in the event of breakage of a roller (103) the value (Vr) detected by the means for detecting (10) being lower than the maximum value (Vmax) and corresponding to the length (Lt) of the portion of main cable (2) comprised between the means for detecting proper and the contact element (3) on which the cable abuts, and processing means (11) which are adapted to compare the detected value (Vr) with the maximum value (Vmax) and, if a difference is detected, to deactivate the means for rotational actuation (105).