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US20120217132A1 - Conveyor belt rip panels and belt rip monitoring - Google Patents

Conveyor belt rip panels and belt rip monitoring Download PDF

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Publication number
US20120217132A1
US20120217132A1 US13/119,858 US200913119858A US2012217132A1 US 20120217132 A1 US20120217132 A1 US 20120217132A1 US 200913119858 A US200913119858 A US 200913119858A US 2012217132 A1 US2012217132 A1 US 2012217132A1
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US
United States
Prior art keywords
rip
panel
conveyor belt
belt
monitoring system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/119,858
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English (en)
Inventor
Mick Twigger
George Mark Myers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fenner Dunlop Americas Inc
Original Assignee
Fenner Dunlop Americas Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fenner Dunlop Americas Inc filed Critical Fenner Dunlop Americas Inc
Priority to US13/119,858 priority Critical patent/US20120217132A1/en
Assigned to FENNER DUNLOP AMERICAS, INC. reassignment FENNER DUNLOP AMERICAS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MYERS, GEORGE MARK, TWIGGER, MICK
Publication of US20120217132A1 publication Critical patent/US20120217132A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/06—Control devices, e.g. for safety, warning or fault-correcting interrupting the drive in case of driving element breakage; Braking or stopping loose load-carriers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating

Definitions

  • the invention relates to systems for monitoring industrial conveyor belt systems, and more particularly to an improved rip panel for use in detecting longitudinal rips in conveyor belts and a system that employs such a panel.
  • Conveyor belts and conveyor systems are widely used in the transport of a variety of materials and products.
  • Conveyor belts may be used in light or heavy materials transport.
  • the belts have reinforcing cords of steel or other material embedded in the belt to provide additional tensile strength.
  • reinforcing cords may be formed of lighter weight non-metallic fibers or cords. In some lightweight applications no reinforcing cords are used.
  • Rip damage can arise in any of these belts during operation. For example, such a rip can occur when the belt is penetrated by an object which has become jammed so that it does not move with the belt. As the belt is driven forcibly against an object that penetrates the belt, a longitudinal rip may develop rapidly along an extended portion of the belt. Such a condition can render the belt unsuitable for the continued transport of material so that the belt must be taken out of service. In extreme cases, the whole belt may require replacement. In other cases, the damaged section must be repaired. As will be appreciated, this can result in financial losses due to the cost of belt repair or replacement and the inconvenience of suspending manufacturing or other operations which rely on continued operation of the conveyor.
  • FIG. 2 is a top plan view on a conveyer system belt 2 and hopper 10 .
  • Transmitters and receivers 5 , 7 are mounted above the belt 2 near loading or discharge sections where most belt rips occur.
  • Antennae 3 are embedded intermittently throughout the conveyor belt.
  • the control box 9 receives power from power source box 11 and sends a signal through the transmitters to each antenna as it passes by the transmitter. The signal passes through the antenna 3 back to the receiver and the control box. The control box receives the signal and evaluates the message. If the signal doesn't reach the receiver, it means a belt tear has interrupted current flow through the antenna 3 . Lack of a transmitted signal indicates that damage has occurred to the belt, and the power to the belt shut off by the control accordingly.
  • a conveyor belt rip panel monitoring system which includes: (1) a conductive loop, (2) a Radio Frequency Identification (RFID) chip electrically connected to the conductive loop, (3) an RFID interrogator positioned to receive information about the conductive loop from the RFID chip, (4) a processing system associated with the RFID interrogator for receiving a signal from the interrogator and processing the signal to obtain a measure of the integrity of the conductive loop, and (5) a user interface for providing an indication of the integrity of the conductive loop to a user.
  • RFID Radio Frequency Identification
  • the RFID interrogation unit can read and write to one RFID chip or a plurality of chips located on or in the belt.
  • the RFID chip may also provide to the interrogator information relating to a rip panel associated with the belt.
  • the rip panel information may include one or more of the members of the group consisting of: rip panel model information, rip panel brand/OEM information, rip panel age information and rip panel repair history.
  • the conductive loop and the RFID chip are connected to a rip detection panel, and the panel is positioned between layers of the conveyor belt.
  • the belt may include a plurality of rip panels, and the panels may be positioned at approximately 200 foot intervals along the length of the belt.
  • a resistor or diode may be electrically connected to the conductive loop and the RFID chip.
  • the conductive loop may be formed from a non-metallic conductive material.
  • the non-metallic conductive loop may include a plurality of legs electrically coupled with the RFID chip.
  • a plurality of loops may be formed from a plurality of legs, and one leg of each loop may be electrically connected to the RFID chip by a resistor or diode having a different resistance so that the interrogator may distinguish each of the loops from another.
  • the processing system may be a programmable logic controller (PLC) rack system, and the interrogation unit may be connected to the processing system via an Ethernet switch.
  • PLC programmable logic controller
  • the system may be operably connected to a data communications network, which may comprise, for example, a facility-wide monitoring system, an Intranet, a virtual private network or the Internet.
  • the RED chip also provides to the interrogator information relating to the model, brand/OEM, age and repair history of the rip panel associated with the belt.
  • the system includes at least one camera for transmitting visual information regarding the conveyor belt to a user.
  • a belt control system may also be operably connected to the monitoring system for directly or indirectly changing the operation of the conveyor belt in response to the signal(s) from the interrogator.
  • FIG. 1 is a side partial diagrammatic view of an exemplary conveyor belt rip monitoring system
  • FIG. 2 is a top plan view of a prior art rip detection system
  • FIG. 3 is a cutaway perspective view of a conveyor belt showing an embodiment of the RFID chip and conductive loop of the invention embedded in a layer of the belt;
  • FIG. 4 is a section view, taken along line 4 - 4 of FIG. 3 , showing an embodiment of a rip panel with an associated RFID chip of the invention
  • FIG. 5 is a plan view of an exemplary rip panel for use with the conveyor system of FIG. 1 ;
  • FIG. 5A is an enlarged plan view of the RFID chip of FIG. 5 ;
  • FIG. 6 is a plan view of another exemplary rip panel for use with the conveyor system of FIG. 1 ;
  • FIG. 7 is a plan view of a further exemplary rip panel for use with the conveyor system of FIG. 1 ;
  • FIG. 8 is a section view, taken along line 8 - 8 of FIG. 5A , showing an embodiment of the RFID chip with material forming the belt extending through a bore formed in the chip.
  • An improved system for monitoring conveyor belts to detect rips that can occur in operation. Specifically, the disclosed system will detect early stages of longitudinal rips in conveyor belts so that the rips can be closely monitored and/or the belt can be stopped before catastrophic failure occurs.
  • a conveyor system 2 may have a reinforced conveyor belt 4 which extends around two end pulleys 6 , 8 .
  • One of the two pulleys may be powered by a motor to drive the belt.
  • the belt 4 may pass under a loading hopper 10 such that material from the hopper 10 is transported by the load-carrying working surface 12 of the belt 2 in a direction to the left in FIG. 1 .
  • At one end pulley 6 the material falls into a second, collection hopper 14 .
  • an RFID interrogation unit 18 is provided.
  • the interrogation may comprise an antenna with a reader/writer. It will be appreciated that although it is illustrated as being under the belt, one or more interrogation units 18 may be provided in any appropriate location with respect to the belt, as long as it can read one or more RFID chips located on or within the belt.
  • the system may have more than one RFID interrogation unit 18 . Where multiple units 18 are provided, they may be positioned at particular locations of interest, such as at the beginning of the belt return section, or near the end pulley 6 at a position downstream of the unloading hopper 14 .
  • the interrogation unit 18 may be connected to a processing system 19 to enable processing of information received from the interrogation unit.
  • the RFID interrogation unit 18 can read and write to one or more RFID chips located in or on the belt 2 .
  • the aforementioned chip(s) may be an RFID chip electronically connected to a conductive loop as described below, or the chip(s) may include an RFID chip located near or otherwise associated with a corresponding rip panel.
  • exemplary conveyor belt 2 may have upper and lower rubber cover layers 20 , 22 between which are sandwiched one or more longitudinal reinforcement layers 24 of reinforcing cords embedded in rubber.
  • these reinforcing cords are made from steel, while in other embodiments they may be non-metallic materials.
  • Yet other embodiments incorporate a fabric layer or no reinforcing layer at all.
  • a rip detection panel 26 may be positioned between one of the cover layers 20 , 22 and the reinforcement layer 24 .
  • the rip detection panel 26 may be assembled as a pre-formed strip in which all the elements of the panel are embedded in rubber or other flexible material. The strip may then be vulcanized into the belt during manufacture to ensure long term belt and panel stability.
  • a conveyor belt 2 may be provided with any appropriate number of such rip panels at longitudinally spaced intervals along the belt 2 in order to ensure that a rip in a section of belt is detected before it becomes too large.
  • rip panels will be positioned at approximately 200 foot intervals along the belt.
  • the illustrated panel 26 comprises a conductive loop 28 having an RFID chip 30 and a resistor or diode 32 coupled thereto.
  • “Panel” for purposes of this description means any material to which the loop 28 , chip 30 , and resistor/diode 32 may be connected, including the conveyor belt layer or layers, and which can be made to travel around end pulleys 6 , 8 in a manner commensurate with the functions of the invention herein described.
  • the RFID chip 30 may include at least one bore 31 , preferably more than one, formed there through so that material 33 during the aforementioned vulcanization or other manufacturing process may extend through the bore(s) 31 and firmly secure the chip 30 to the belt or the panel accordingly, as shown for example in FIG. 8 .
  • the resistor or diode 32 may be used for identification of open circuit, short circuit, or healthy panel conditions depending upon the current sensed by the RFID chip 30 as it passes the interrogation unit 18 .
  • the interrogation unit 18 positioned on the conveyor structure will switch on the RFID chip 30 as it passes the unit.
  • the RFID chip 30 will identify a measured current/resistance and will transmit representative information back to the interrogation unit for analysis. This information may be used for sensing a variety of conditions, including a rip condition. For example, the RFID chip 30 may send a 1-bit to the interrogation unit to represent a good condition, and a 0-bit to represent a damage (rip) condition.
  • the interrogation unit 18 may be connected to a processing system 19 , which in one embodiment is a programmable logic controller (PLC) rack system.
  • PLC programmable logic controller
  • the interrogation unit 18 may be connected to the processing system 19 via an Ethernet switch 34 .
  • the processing system 19 may have a processor 36 capable of executing instructions for analyzing the received signals and for assessing a condition of one or more rip panels 26 based on the received signals.
  • the processing system 19 can determine the condition of that panel.
  • the system may determine that a rip has been detected, the severity of the rip, whether the panel itself has degraded over time, and so on.
  • the executable instructions run by the processor 36 may be customized by the user to analyze the signals and to trigger alarms (for cases in which slight rips have been detected), or to stop the belt automatically in cases where large rips are detected.
  • a baseline reading from each RFID chip 30 of each rip panel 26 may be obtained during a first cycle of the belt around the pulleys 6 , 8 .
  • the reading from each RFID chip 30 may be compared with the original reading, and the occurrence of any significant changes noted to determine whether the change is indicative of a rip, or other condition in the belt.
  • each panel 26 may have a resistor/diode 32 with a unique resistance to provide further level of panel identification.
  • the RFID chip 30 may itself provide automatic identification of the individual panels 26 . Examples of such identification information include the model, brand/original equipment manufacturer (OEM), age, repair history, if any, and the like.
  • the conductive loop 28 may comprise any of a variety of conductive materials, such as metal and non-metallic conductors.
  • suitable metal conductors include copper and platinum.
  • suitable non-metallic conductor may include graphite, or an elastomeric conductive material such as that manufactured by NanoSonic, Inc., of Blacksburg, Va., sold under the trademark “METALRUBBER.”
  • the conductive loop can be in wire or ribbon form, as desired, which can be of suitably low resistivity such that it can be operated in conjunction with the RFID chip.
  • One substantial benefit of using a non-metallic conducting material to form the conductive loop 28 is that it is expected to add little to the overall lateral stiffness of the conveyor belt 2 .
  • Conventional rip panels that utilize a plurality of laterally-oriented conductive metal wires can add substantial lateral stiffness to the conveyor belt. This increased lateral stiffness may make it more difficult to “trough” the belt (i.e., where the angled rollers of the conveyor structure force the belt to conform to a V or U-shape in order to confine and carry the load material) in operation.
  • forced troughing of the laterally stiff rip panels can cause premature failure of the rip panel due to the fatigue of repeated bending of the metal wires or cords.
  • rip panel 126 comprises a plurality of conductive legs 128 that are electrically coupled with an RFID chip 130 .
  • the RFID chip 130 of this embodiment may have any or all of the characteristics of the RFD chip 30 described in relation to FIG. 5 .
  • the RFID chip 130 may be configured to provide information to the interrogation unit 18 relating to the integrity of one or more of the conductive legs 128 (e.g.; whether a partial or full rip has occurred in one or both), and may also provide detailed information about the panel such as model, brand, age, repair history (if any), and the like.
  • the RFID chip 130 passes the interrogation unit 18 it will be switched on. It will send a current through the legs 128 and will send a digital bit to the interrogation unit indicating whether the circuit is closed (good) or open (bad). It may also provide an indication if one or more legs are only partially ripped.
  • Another RFID chip like the one shown in association with the previously described rip panel 26 , may provide information about the belt.
  • FIG. 7 shows an alternative embodiment of a non-metallic rip panel 226 incorporating a plurality of loops formed from a plurality of conductive legs 228 electrically coupled to an RFID chip 230 .
  • the RFID chip 230 of this embodiment may have any or all of the characteristics of the RFID chips 30 , 130 described in relation to FIGS. 5 and 6 .
  • the RFID chip 230 may be configured to provide information to the interrogation unit 18 relating to the integrity of one or more of the conductive legs 228 (e.g., whether a partial or full rip has occurred in one or both), and may also provide detailed information about the panel such as model, brand, age, repair history (if any), and the like.
  • An additional chip (not shown) may be associated with the panel 226 like that shown in FIG. 5 with respect to the panel 26 of that embodiment.
  • a single RFID chip 230 may be used to monitor multiple loops, simultaneously, and to provide the interrogation unit with information regarding the ongoing integrity of the individual legs 228 of the rip panel 226 .
  • This arrangement may provide more detailed information about a rip in the conveyor belt 2 as compared to previous embodiments due to its greater longitudinal extent (owing to the multiple-loop configuration). Thus, it may be possible to more accurately estimate the extent or length of a longitudinal rip in the belt by knowing exactly how many legs 228 have been broken by the rip.
  • one leg of each loop is connected to the RFID chip 230 by a resistor (or diode) 232 having a unique resistance so that the RFID can immediately determine which leg has been breached by the rip.
  • the RFID 230 will be switched on. It will send a current through the legs 228 and will send a digital bit to the interrogation unit indicating whether the circuit is healthy or open/damaged.
  • the RFID may send a signal representing 1-1-1-1 to show a typical (i.e., good) condition.
  • the RFID chip 230 may send a signal representing 0-1-1-1 to show a damage condition in the first leg. This damage condition may then be interpreted as a rip in the belt. Damage to more than one leg would be indicative of a longer rip.
  • the disclosed arrangement may also provide an indication if one or more legs are only partially ripped.
  • the system 1 may also comprise a camera 38 ( FIG. 1 ) for transmitting visual information regarding a top surface 12 of the belt cover to enable the user to correlate information provided by the system with a visual indication of the belt at a particular location. While the illustrated embodiment shows the camera 38 positioned beneath the belt, it will be appreciated that the camera could be positioned in any desired location to obtain images of the belt top or bottom surfaces.
  • multiple cameras 38 may also be provided, including cameras having high definition capabilities. The cameras may be adjustable to pan a desired location, and they may also have zoom functionality to focus on a particular area of interest.
  • the signal from the camera 38 can be routed to the processing system 19 through the Ethernet switch 34 .
  • the camera 38 may be controlled (e.g., to take continuous video images, or to take a snapshot at a targeted location) by the processing system 19 .
  • the processing system may signal the camera to automatically take a picture based on a triggering event (e.g., where a rip condition is sensed).
  • the processing system 19 may also provide a connection to a belt control system 40 to control the belt 2 as desired.
  • the processing system 19 may be used to instruct the belt control system 40 to slow the belt speed and/or to stop a targeted portion of the belt at a specific location within the mine so that the belt can be inspected and/or repaired.
  • the processing system 19 may instruct the belt control system 40 to immediately stop the belt 2 regardless of its position.
  • the system 1 may further comprise user/operator display 42 for providing information regarding the status of the rip panels 26 in the system. Any or all of the information in this display may be viewed locally, or it may be transmitted to remote users via an appropriate data communications network such as a company's intranet, virtual private network (VPN), the Internet or the like to enable global viewing and control of the system 1 .
  • the information can also be e-mailed to one or more individuals (including photographs) so that a remote determination can be made regarding the damage.

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US13/119,858 2008-09-19 2009-09-16 Conveyor belt rip panels and belt rip monitoring Abandoned US20120217132A1 (en)

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US13/119,858 US20120217132A1 (en) 2008-09-19 2009-09-16 Conveyor belt rip panels and belt rip monitoring

Applications Claiming Priority (5)

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US9837808P 2008-09-19 2008-09-19
US9838908P 2008-09-19 2008-09-19
US9846108P 2008-09-19 2008-09-19
PCT/US2009/057063 WO2010033526A1 (fr) 2008-09-19 2009-09-16 Panneaux déchirables pour bande transporteuse et surveillance des déchirures de la bande
US13/119,858 US20120217132A1 (en) 2008-09-19 2009-09-16 Conveyor belt rip panels and belt rip monitoring

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US20120217132A1 true US20120217132A1 (en) 2012-08-30

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US13/119,912 Active 2030-07-21 US8657105B2 (en) 2008-09-19 2009-09-16 System and method for controlling a conveyor belt condition monitoring system
US13/119,858 Abandoned US20120217132A1 (en) 2008-09-19 2009-09-16 Conveyor belt rip panels and belt rip monitoring
US13/119,894 Active 2030-04-08 US8662290B2 (en) 2008-09-19 2009-09-16 Conveyor belt condition monitoring system

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US13/119,912 Active 2030-07-21 US8657105B2 (en) 2008-09-19 2009-09-16 System and method for controlling a conveyor belt condition monitoring system

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US13/119,894 Active 2030-04-08 US8662290B2 (en) 2008-09-19 2009-09-16 Conveyor belt condition monitoring system

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AU (3) AU2009293401B2 (fr)
CA (1) CA2737605C (fr)
WO (3) WO2010033527A1 (fr)

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US20120168281A1 (en) 2012-07-05
US8657105B2 (en) 2014-02-25
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AU2009293399B2 (en) 2015-07-30
WO2010033527A1 (fr) 2010-03-25
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US8662290B2 (en) 2014-03-04
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