TECHNICAL FIELD

[0001] This disclosure relates generally to conveyor belt systems, and to apparatus and components used in such systems. More particularly, the disclosure is concerned with arrangements for changing the direction of travel of a conveyor belt.

BACKGROUND ART

[0002] Conveyor belt systems generally comprise an endless belt, which is adapted to run on a series of rollers, including driven and idler rollers. In many applications it is necessary to change the direction of travel of a conveyor belt. Currently known apparatus for performing this function are relatively complicated and can take up a significant amount of space. This can be a problem where space is limited, for example, in underground mining sites wherein the space within mining tunnels can be extremely restrictive.

SUMMARY OF DISCLOSURE

[0003] In a first aspect, embodiments are disclosed of a conveyor belt turning pulley for use in conveyor belt turning apparatus, the pulley comprising a pulley main body having opposed ends and an outer surface, the pulley main body in use being mounted for rotation about a pulley rotation axis which extends between the ends of the pulley main body, the pulley further including an array of rollers operatively mounted to the outer surface of the pulley main body, the rollers each being mounted for rotation about a roller rotation axis.

[0004] In certain embodiments, the roller rotation axes extend in a lateral direction with respect to the pulley rotation axis.

[0005] In certain embodiments, the roller rotation axes extend generally in the direction of the outer surface of the pulley main body in the region where the roller is mounted to the outer surface.

[0006] In certain embodiments, the pulley main body is generally circular when viewed in the direction of the pulley rotation axis and the roller rotating axes extend in a direction parallel to a tangential line from the outer surface in the region where the roller is mounted thereto. [0007] In certain embodiments, the rollers are arranged in a series of groups which are disposed side-by-side in the direction of the pulley rotation axis, each group including a plurality of said rollers located around a peripheral region of the outer surface of the pulley main body.

[0008] In certain embodiments, each group comprises a plurality of mounting units arranged around the periphery of the outer surface of the pulley main body, each mounting unit having associated there with one or more of the rollers.

[0009] In certain embodiments, the mounting units are disposed in one or more planes which is/are at substantially right angles to the pulley rotation axis.

[0010] In certain embodiments, each mounting unit includes two rollers arranged side-by-side with respect to the direction of the pulley rotation axis.

[0011] In certain embodiments, adjacent ends of the mounting units in one group are offset from adjacent ends of the mounting units in an adjacent group with respect to the direction of the pulley rotation axis.

[0012] In certain embodiments, the pulley further includes an extension member operatively connected to one of the ends of the pulley main body when in a fitted position, said extension member including an array of said rollers mounted to an outer surface of the extension member.

[0013] In certain embodiments, the extension member includes a plug portion which is adapted to be received in a hollow portion of the pulley main body at said one end.

[0014] In certain embodiments, the rollers on the extension member are arranged in one or more groups which are disposed side-by-side in the direction of the pulley axis when in the fitted position.

[0015] In a second aspect, embodiments are disclosed of conveyor belt turning apparatus for use in a conveyor belt system, the conveyor belt system including an endless conveyor belt arranged for movement along a travel path and including a conveying line section and a return line section, the conveyor belt turning apparatus comprising a main support structure and at least first and second conveyor belt turning pulleys operatively mounted to the support structure for rotation about respective axes of rotation and arranged so as to change the travel path direction of at least one of the conveyor line sections when in use.

[0016] In certain embodiments, one of the belt turning pulleys is spaced from the other belt turning pulley in an upwardly extending direction.

[0017] In certain embodiments, the axes of rotation of the first and second conveyor belt turning pulleys are generally parallel to one another.

[0018] In certain embodiments, the axes of rotation of the first and second conveyor belt turning pulleys are inclined with respect to one another.

[0019] In certain embodiments, the axes of rotation of the first and second conveyor belt turning pulleys are laterally spaced when viewed in plan.

[0020] In certain embodiments, the conveyor belt turning pulleys are in accordance with that described earlier.

[0021] In a third aspect, embodiments are disclosed of a roller cartridge including at least one roller, adapted to be operably mounted to an outer surface of a main body of a conveyor belt pulley, wherein a roller rotation axis extends in a lateral direction relative to a pulley rotation axis.

[0022] In a fourth aspect, embodiments are disclosed of an extension member adapted to be fitted to an end of conveyor belt pulley to thereby increase the length of said pulley.

[0023] In certain embodiments the extension member includes a plug portion adapted to be received within a hollow body of said conveyor belt pulley.

[0024] In a fifth aspect, embodiments are disclosed of a conveyor belt system, including: an endless conveyor belt including a conveying line section and a return line section; a conveyor belt turning apparatus comprising a plurality of belt turning pulleys, configured so as to operatively engage one of said line sections, said belt turning pulleys being arranged to change the direction of travel the said one of said line sections engaged thereby; said belt turning pulleys each having a rotation axis, the belt turning pulleys being disposed one above the other with their rotation axes being generally horizontally disposed.

[0025] In certain embodiments, the conveyor belt turning apparatus may be in accordance with any one of those described earlier.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Notwithstanding any other forms which may fall within the scope of the method and apparatus set forth in the summary, specific embodiments of the method and apparatus will now be described by way of example and with reference to the accompanying drawing in which:

[0027] Figure 1 is a side elevation of a conveyor belt turning pulley according to one embodiment;

[0028] Figure 2 is an end view of the pulley shown in figure 1;

[0029] Figures 3(a) to 3(d) are various views of a first example embodiment of a roller carriage part of the pulley shown in figure 1;

[0030] Figures 4(a) to 4(d) are various views of a second example embodiment of the roller carriage part of the pulley shown in figure 1;

[0031] Figures 5(a) to 5(d) are various views of a first example embodiment of a roller part for the cartridge shown in figures 3(a) to 3(d);

[0032] Figures 6(a) to 6(d) shows various views of a second example embodiment of a roller part for the cartridge shown in figures 4(a) to 4(d);

[0033] Figures 7(a) and 7(b) are sectional schematic views of an extension part of the pulley;

[0034] Figures 8(a) to 8(e) detail an example embodiment of a pulley incorporating an extension part;

[0035] Figures 9(a) to 9(e) are various views of a belt turning apparatus according to one embodiment;

[0036] Figure 10 are illustrations of part of a conveyor belt system which incorporates the apparatus shown in figures 9(a) to 9(e);

[0037] Figures 11(a) to 11(c) are various views of a belt turning apparatus in accordance with another embodiment;

[0038] Figures 12(a) to 12(d) are various views of a conveyor belt system which incorporates belt turning apparatus shown in figures 11(a) to 11(c); [0039] Figures 13 to 18 are various views of a belt turning apparatus according to another embodiment; and

[0040] Figures 19 to 22 are various views of the conveyor belt system incorporating belt turning apparatus shown in figures 13 to 18.

DETAILED DESCRIPTION

[0041] Belt turning apparatus and components therefor are suitable for use in belt conveying systems, examples of which are hereinafter described. The belt conveying systems 100 comprise an endless conveyor belt 101 which is movable along a travel path and include a conveying line section 102 along which material or articles are carried and a return line section 104. The conveyor belt systems 100 include belt turning stations 110 where belt turning apparatus are installed.

[0042] Figures 1 and 2 illustrate a conveyor belt turning pulley 10 which is for use in conveyor belt turning apparatus 70, 170 and 270, as shown for example in figures 9, 11 and 13. The pulley 10 comprises a main body 12 which, in the form shown, is a shell having opposed ends 13 and 14, and, an outer surface 16. The main body 12, in use, is mounted for rotation about a rotation axisX-X, which extends between its ends 13 and 14. In the embodiments shown, the outer surface 16 is circular when viewed in the direction of the rotation axis X-X, and, the main body is of a hollow cylindrical constmction.

[0043] The pulley 10 further includes an array or series of rollers 30 operatively mounted on the outer surface 16 of the main body. Forthe sake of clarity, only some of the rollers 30 are itemized. The rollers 30 are each mounted for rotation about a roller rotation axis Y-Y (see figure 3(b) for example). As shown, the roller rotation axes Y-Y extend in a lateral direction with respect to the direction of the pulley rotation axis X-X. The roller rotation axes Y-Y can be seen to extend generally in the direction of the peripheral of the outer surface 16 of the main body 12 of the pulley 10, when viewed from one end thereof in the region where the roller 30 is mounted to the outer surface 16 of the main body 12 of the pulley 10. In the embodiment shown, the outer surface 16 is circular when viewed from one end, and, in this particular embodiment, the roller rotation axes Y-Y extend in a direction substantially parallel to the tangential direction with respect to the outer surface 16.

[0044] As shown, the rollers 30 are arranged in a series of groups 30A-30L, the rollers in each group extending around the periphery of the outer surface of the body or shell. The rollers in each group are associated with a senes of cartndges or mountings 32, the mountings being disposed around the periphery of the outer surface 16 of the main body of the pulley. As shown, the groups 30A-30L are arranged side by side along the main body of the pulley in the direction of rotation axis X-X. As is apparent, the rollers in each group are disposed in a general plane which is arranged laterally and preferably at 90° to the pulley rotation axis X-X. In figure 1, the pulley 10 comprises twelve groups of rollers, however, more or less groups may be provided depending on the particular application.

[0045] As illustrated in figures 3 and 4, each mounting or cartridge 32 may comprise two rollers 33 and 34 arranged side by side. The mountings 32 in each group are disposed adjacent one another with closely adjacent end regions 36 therebetween. The groups 30A -30L are disposed side by side in the direction of the rotation axis X-X of the main body or shell 12. As shown, the adjacent end regions 36 of the rollers in one group are offset to the adjacent end regions of the rollers in an adjacent group. This is illustrated in figure 1, for example, with reference to groups 30K and 30L.

[0046] The rollers 33 and 34 in each cartridge or mounting 32 are fitted to a support 40 which in turn is operatively secured to the outer surface 16 of the body 12. The support 40 comprises a main structure 41 , which includes a base wall 42, and end walls 43 and 44 extending from opposite side of the base wall 42, thereby providing for a substantially U-shaped member. The end walls 43 and 44 are the ends 36 of each cartridge or mounting 32. The support 40 further includes keeper plates 45 to which the rollers 30 are rotationally mounted. Each roller 30 has a set screw 46 associated therewith.

[0047] The cartridge illustrated in figure 4 is similar to that of figure 3 in function, but with slight variations to the design.

[0048] As shown in detail in figures 5 and 6, the rollers 30 may comprise a roller body 50 having an outer surface 51 which is generally circular in shape when viewed in the direction of the rotation axis Y-Y. The outer surface 51 also has a slightly curved or outwardly bowed profile from one end of the roller body to the other end. The roller body 50 is carried on a roller shaft 53 via a series of ball bearings 55, seal plates 58, closing cap 59, circlips 56 and seals 57.

[0049] The roller 30 shown in figure 6 is similar to the roller of figure 5 in function, but with some modifications to the profile and other details thereof. [0050] The pulley 10 further includes stub shafts 20 and 21 operatively mounted directly to the ends 13 and 14 of the main body. As shown in schematic views in figures 7 (a) and 7 (b), one or more extension member inserts 26 may optionally be fitted to one or both ends 13 and 14 of the main body, in order to increase the length of the pulley to accommodate belts of greater width during a belt turning operation where a longer pulley is required due to it extending at an angle which is lateral, and typically 45 degrees, to the belt. In this arrangement the stub shafts 20 and 21 are operatively fitted to the or each extension insert 26. The inserts 26 comprise a plug section 27 which is receivable within the hollow body 12, and a head 28, to which the stub shaft 21 is secured. The stub shafts 20 and 21 are operatively fitted to respective bearing assemblies 23 and 25, and, in the embodiment illustrated, one of the bearing housings 23 is a fixed bearing housing and the other housing 25 is a floating bearing housing. The head 28 of the extension member may include one or more groups of rollers thereon configured in a similar fashion to those groups described earlier.

[0051] In figure 8 is detailed an extension member 26 being fitted to one end of a pulley 10. Figure 8 (a) shows and exploded isometric view of the attachment piece 26 and other ancillary components spaced apart from a pulley 10, whilst figure 8(b) shows an elevational view thereof. Figure 8 (c) shows an elevational view with the extension piece 26 secured to the pulley 10, with figure 8 (d) and 8 (e) showing end and cross-sectional views, respectively. As shown, the extension member 26 has a group of rollers 30M mounted thereto. Thus, the number of groups of rollers on an existing pulley can be increased.

[0052] As hereinbefore mentioned, the pulleys 10 are suitable for use in a conveyor belt turning apparatus for conveyor belt systems. One example of a conveyor belt turning apparatus is illustrated in figures 9(a) to 9(e). As shown, the apparatus generally indicated at 70, comprises a main support structure 72 which, in the form shown, comprises a frame 73 comprising a series of uprights 74 and cross members 75, which together form a rigid structure. In this particular embodiment, two pulleys 10 A and 10B are operatively mounted to the support structure 72. An upper pulley 10A is disposed above a lower pulley 10B in spaced relation thereto, the pulleys being configured with their rotation axes X-X, as identified in figure 1, substantially parallel and one above the other.

[0053] As shown in figures 9(a) to 9(e), the apparatus 70 may further include a series of belt wander or drift switches 78 which are used for drift or wander monitoring so as to protect the system from damage in the event of unwanted belt dnft dunng operation. Further, as shown in figure 9(b), the apparatus includes a centralised lubrication system for greasing the bearings and seals of the apparatus. A detail of this feature is also shown in figure 9(b). Its function is to provide grease to pulleys and seals during regular maintenance for example.

[0054] Figures 11(a) to 11(c) illustrate abelt turning apparatus according to another embodiment. The drawings show the apparatus in an installed position at a belt turning station in a conveyor belt system. The apparatus 170 comprises a main support structure 172 to which the support pulleys 10A and 10B are operatively mounted. The support structure 172 includes a base frame section 173 to which one of the pulleys 10B is mounted. The support structure 172 further includes upright frame members 174 which extend upwardly from the base frame section 173. There are two upright frame members 174 which are spaced apart from one another, and pulley 10A is secured at its ends to respective upright frame members 174. The pulley 10A is in spaced apart relation to and above the pulley 10B. As shown, the axes of rotation of the pulleys are angularly inclined with respect to one another. In the embodiment illustrated, the axes of rotation are at substantially right angles to one another when viewed in plan.

[0055] As shown with reference to figures 11(a) to 11(c), the upper pulley 10A and the lower pulley 10B are configured with their rotation axes inclined with respect to one another. Different configurations of pulleys, as described, enable the apparatus to function in different modes of operation when the apparatus is installed in a belt conveying system.

[0056] As described earlier, the endless conveyor belt 101 in a conveyor belt system 100, includes a path of travel which provides for conveying line section along which material or articles are carried, and a return line section. Figures 10 and 12 illustrate conveyor belt systems which include a belt turning station 110 at which belt turning apparatus, of the types described earlier, are located.

[0057] The conveying line section 102 and the return line section 104 of the conveyor belt each include an entry zone 105 and 107, where the conveyor belt enters the belt turning station 110, and, an exit zone 106 and 108, where the conveyor belt exits from the turning station 110.

[0058] As mentioned earlier, the pulleys in the belt turning apparatus can be arranged in different configurations, when installed, so as to be capable of use in different modes of operation. In one mode, the pulleys are configured so as to change the direction of travel of the return line section of the conveyor belt, and, in another mode the pulleys are configured to change the direction of travel of the conveying line section. These are described in some detail below with reference to the drawings.

[0059] Figure 10 illustrates a part of one type of conveyor belt system 100, and figures 11 and 12 illustrate a part of another type of conveyor belt system 100. In each case, the system 100 includes an endless conveyor belt 101, which moves along a path of travel, and includes a conveying line section 102, upon which material or articles canbe carried, and a return line section 104. Each system 100 includes a belt turning station 110 at which the direction of travel of a section of the conveyor belt 100 can be changed. Belt turning apparatus 70 or 170 of the type described above can be located at the station 110.

[0060] Figure 10 illustrates a system where the return line section of the conveyor belt changes in direction as it passes through the turning station 110. In this mode of operation, the conveying line section 102 passes through the station 110 without being affected by the belt turning apparatus. The belt turning apparatus used in this mode of operation is described with reference to figure 9. In this arrangement the pulleys 10A and 10B are disposed one above the other with their rotation axes X-X extending in substantially the same direction.

[0061] As the return line section 104 enters the turning station 110 at the entry zone 107, it is engaged by the rollers 10A and 10B so that the return line section is redirected in a direction of travel which is transverse to the direction of travel of the conveying line section 102. This portion of the return line section is referred to as the “loop take-up line” 115 of the conveyor belt. The loop take-up line of the conveyor belt extends about an end roller (not shown). Additional guide rollers may be provided to assist guiding of the conveyor belt, if necessary. As the belt moves about the rollers 10A and 10B, it will however be appreciated that these guide rollers are optional and not always necessary. The return line section is redirected back to the turning station 110 where it exits at the exit zone 108. In this embodiment the conveying line section 102 passes through the turning station 110 unobstructed. That is, there is no engagement of the conveying line section 102 with the pulleys 10A and 10B to cause the conveying line section 102 to change direction.

[0062] The configuration enables that drive rollers for the system can be provided in the loop take-up section of the return line of the conveyor belt. This has particular advantages in longwall mining where the machinery to drive the drive rollers may be installed in a section of the mine in which the core mining operation and/or the conveying of mined minerals is not in the mam mine tunnel. That is, this “loop take-up” section of the conveyor belt may be installed remotely from the mining end of the conveyor belt such that it does not interfere with the mining operation, per se. The “loop take-up” section is preferably adjustable in position along the length of the conveyor belt, and in particular, along the length of the return line of the conveyor belt, such that the conveying line of the conveyor belt may be quickly and easily adjusted in length as the mine site advances.

[0063] In the arrangement shown in figures 11 and 12, the direction of travel of the conveying line section 102 of the conveyor belt 101 is changed. In this arrangement the pulleys 10A and 10B are configured with their rotation axes X-X inclined with respect to one another such as for example at about 90 degrees. In this case, the rotation axes are disposed in substantially horizontal planes. In this arrangement, the conveying line section enters the station 110 and engages one of the pulleys 10A and is redirected at right angles away from the station 110.

[0064] The conveying line section 102 enters the turning station 110 at an entry zone 105, where it travels around one of the pulleys (the upper pulley) and is redirected to a transfer or orientation region 116, from where it is returned to the turning station 110. The conveying line section passes from the transfer region 116, through the turning station 110, to an exit zone 107, from which it exits the work station. The movement of the conveying line section through the turning station from the transfer region 116 to the exit zone is unobstructed by the pulleys. Material carried on the conveying line section is discharged from the entry zone 105 to the exit zone 107. The arrows shown on the conveying line section 102 in figures 12(b) and 12(c) represent the travel path of material carried on the conveying line section 102 through the turning station 110. As best illustrated in figure 12(c) material carried on the conveying line section 102 at the entry zone 105 is discharged before the conveying line section 102 passes to the transfer region 116 onto that part of the conveying line section 102 at the exit zone 107.

[0065] In this embodiment the system includes a further material loading conveyor 120 which can load material onto that part of the conveying line section in the transfer region 116. This material passes through the turning station where it merges with the other material. Again, the material line of travel is indicated by the arrows of the conveying line section 102.

[0066] Figures 13 to 18 illustrate a further embodiment of conveyor belt turning apparatus 270. The apparatus is similar in structure to that described with reference to figures 9(a) to 9(e) except that the pulleys 10A and 10B are orientated relative to one another in a different configuration. As shown, the apparatus 270 comprises a main support structure 272 which comprises a base 271 and an upper frame 273 comprising uprights 274 and cross members 275 which together form a rigid structure to which the pulleys 10A and 10B are operatively mounted. In the embodiment illustrated, the rotation axes of the pulleys are displaced laterally with respect to one another and parallel to one another. Furthermore, pulley 10B is displaced upwardly from pulley 10A. This configuration is clearly illustrated in figure 18.

[0067] A belt turning station 110 incorporating the belt turning apparatus 270 illustrated in figures 13 to 18 is shown in figures 19 and 20. The belt turning apparatus 270 is arranged to change the travel direction of the return line section 104. Guide roller systems 111, 112 and 113 assist in controlling the delivery and exit of the return line sections 104 of the conveyor belt to and from the belt turning apparatus 270 (the belt turning apparatus 70 and 170 as shown in figures 9 and 11 may also include guide roller control systems where needed). A guard fence 114 may be provided around the belt turning station 110.

[0068] Figures 21 and 22 illustrate a conveyor belt system incorporating belt turning apparatus 270 as described earlier. Conveying line section 102 travels from the tail end of the line, through the belt turning station 110 to material transfer region. The conveying line section is unobstructed by the pulleys as it passes through the belt turning station 110. The return line section 104 passes through the belt turning station 110 with its travel path being changed by the pulleys. It is arranged to travel to a loop take up and drive region.

[0069] In the forgoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “front” and “rear”, “inner” and “outer”, “above”, “below”, “upper” and “lower” and the like are used as words of convenience to provide reference points and are not to be constmed as limiting terms.

[0070] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. [0071] In this specification the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of’. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0072] In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, addition and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

[0073] Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g. aspects of one embodiment may be combined with aspects of another embodiment to realise yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

[0074] The reference numerals in the following claims do not in any way limit the scope of the respective claims.

TABLE OF PARTS

Pulley 10

Main body or shell 12

Ends 13/14

Outer surface 16

Pulley rotation axis X-X

Stub shafts 20/21

Bearing assemblies 23/25

Inserts 26

Plug section 27

Head 28

Rollers 30

Roller rotation axis Y-Y

Roller groups 30A-30L

Roller mounting 32

Rollers in mounting 33/34

End regions 36

Support 40

Main structure 41

Base wall 42

Side walls 43/44

Keeper plates 45

Set screw 46

Roller body 50

Outer surface 51

Roller shaft 53

Ball bearings 55

Seal plates 56

Circlips 57

Seals 58

Conveyor belt turning apparatus 70/170/270

Support structure 72/172/272

Frame 73 Uprights 74/174/274

Cross members 75

Lubrication system 77

Upper pulley 10A

Lower pulley 10B

Belt drift switch 78

Conveyor belt system 100

Conveyor belt 101

Conveying line 102

Return line 104

Turning station 110

Entry zone 105

Exit zone 106

Entry zone 107

Exit zone 108

Guide roller systems 111/112/113

Guide fence 114

Loop take-up line 115

Transfer region 116

Loading conveyor 120

Apparatus 270

Base 271

Main support Structure 272

Upper frame 273

Uprights 274

Cross members 275