FIELD

[0001] The field to which the disclosure generally relates is conveyor belts.

BACKGROUND

[0002] Conveyor belts are widely used for moving minerals, coal, and a wide variety of manufactured products from one point to another. Heavy duty conveyor belts used in mining operations can extend over distances of several miles and represent a high cost component of an industrial material handling operation. Unfortunately, such conveyor belts are susceptible to damage from the material transported thereon and a rip, slit, cut or tear may develop within the belt. For instance, sharp edges of the material being transported can gouge the surface of the belt and that can result in a rip developing. Conveyor belt segments are spliced together during installation to form a continuous loop of conveyor belting. During the operation of this conveyor belt it is susceptible to damage and the integrity of the conveyor belt and these splices can be compromised and require repairs or replacement.

[0003] In order to minimize the effects of potential longitudinal rips or transverse tears due to large cord damages, mines can utilize sensors to monitor for these conditions and alert the mine to an existing or potential catastrophic event. Conveyor belts that rip longitudinally often utilize rip detection systems to contain the damage being done by the rip in order to minimize downtime. Additionally, in steel cord belts, damaged steel cords within the conveyor belt or splice defects can be magnetically monitored and repaired proactively to avoid a catastrophic event. The cost of repairing a heavy conveyor belt and cleaning up material spilled as a result of the damage can be substantial. In cases where such damage is not detected and repaired promptly, the damage can propagate as a longitudinal rip along the length of the belt or across the width of the belt as a transverse tear with continued use of the conveyor system resulting in additional conveyor belt damage and a larger downtime event for the end user. These same issues apply also to fabric belt applications where it is accordingly desirable to detect damage to the fabric splice and to repair or replace the damaged splice before catastrophic failure occurs. By doing so, the extent of the damage to the belt can be minimized, the repair can be simplified, and the spillage of material being conveyed as well as associated downtime can be reduced or avoided and the life of the conveyor belt can be extended.

[0004] Over the years, a number of systems have been developed for detecting belt damage and for automatically stopping further movement of the belt after the damage occurs. It is well known to employ inductive antennae within conveyor belts as part of a rip detection system. In a typical system, sensors in the form of loops of conductive wire are affixed or embedded in the belt and provide a rip detection utility as part of an overall rip detection system. Rip detection is achieved through the inferential detection of an “open circuit” condition in one or more of the sensor loops in the belt. Typically, an electrical energy source external to the belt is inductively or capacitively coupled to a sensor loop in the belt. A break in the conductive wire loop of the sensor may be detected by a remote transmitter/receiver (exciter/detector). Disposition of a plurality of such sensors at intervals along the conveyor may be effected with each sensor passing within read range of one or more exciter/detectors at various locations. A rip will encounter and damage a proximal sensor loop and the existence of the tear will be detected when the proximal sensor loop damage is detected as an open circuit by the reader at its next pass. In this manner, the existence of a rip will be promptly detected and repaired with further damage to the belt being minimized.

FIGURES

[0005] Fig. 1 is a diagram illustrating a conveyor system 1 in accordance with one or more embodiments.

[0006] Fig. 2 is a schematic cross-sectional view of a embedded magnetic element showing a plurality of rip detection wires therein wherein the embedded magnetic element has not been subjected to belt damage. [0007] Fig. 3 illustrates the magnetic field image of the embedded magnetic element shown in Fig. 2 (without belt damage).

[0008] Fig. 4 is a diagram illustrating a cross sectional view of a conveyor belt splice 400 in accordance with one or more embodiments.

[0009] Fig. 5 is a diagram illustrating a view of a conveyor belt splice 500 in accordance with one or more embodiments.

[0010] Fig. 6 shows a plurality of example rip inserts for conveyor belt splices in accordance with one or more embodiments.

[0011] Fig. 7 shows a plurality of example rip inserts for conveyor belt splices in accordance with one or more embodiments.

[0012] Fig. 8 shows a plurality of example rip inserts for conveyor belt splices in accordance with one or more embodiments.

[0013] Fig. 9 shows a plurality of example rip inserts for conveyor belt splices in accordance with one or more embodiments.

DETAILED DESCRIPTION

[0014] The following description of the variations is merely illustrative in nature and is in no way intended to limit the scope of the disclosure, its application, or uses. The description is presented herein solely for the purpose of illustrating the various embodiments of the disclosure and should not be construed as a limitation to the scope and applicability of the disclosure. In the summary of the disclosure and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the disclosure and this detailed description, it should be understood that a value range listed or described as being useful, suitable, or the like, is intended that any and every value within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors had possession of the entire range and all points within the range.

[0015] Unless expressly stated to the contrary, "or" refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0016] In addition, use of the "a" or "an" are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of concepts according to the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless otherwise stated.

[0017] The terminology and phraseology used herein is for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited.

[0018] Also, as used herein any references to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily referring to the same embodiment.

[0019] The conveyor belts which can be monitored in accordance with this invention have an elastomeric body (carcass section) with a load carrying surface on the top side thereof and a pulley engaging surface on the bottom side thereof. These conveyor belts will also include at least one reinforcement ply disposed within the elastomeric body and at least one splice making the belt an endless loop. The splices will typically connect various segments of the belt together to form an endless belt which is comprised of multiple segments which are joined together by the splices.

[0020] The splices will typically be spaced incrementally along the length of the conveyor belt. The splices can be single stage splices, two stage splices, three stage splices, or multiple stage splices having four or more stages.

[0021] The elastomeric body will normally include plies of fabric that typically run longitudinally within the conveyor belt. The conveyor belts of this invention can optionally also contain conventional inductive belt damage sensor loops including embedded transducer elements. Rip detection systems of this type are described in U.S. Pat. No. 4,621 ,727, U.S. Pat. No. 4,854,446, U.S. Pat. No. 6,715,602, and U.S. Pat. No. 8,069,975. The teachings of U.S. Pat. No. 4,621 ,727, U.S. Pat. No. 4,854,446, U.S. Pat. No. 6,715,602, and U.S. Pat. No. 8,069,975 are incorporated herein by reference for the purpose of disclosing conventional rip detection and identification systems that can be used in conjunction with this invention. However, it may be desirable for the system of this invention to be void of rip detection loops and embedded magnetic elements. In any case, rip detection loops or embedded magnetic elements are not needed in implementing the system of this invention.

[0022] One or more embodiments are disclosed that have a magnetic element or a transverse array of magnetic elements embedded in the splice. As a result, a full width of the splice can be monitored with a full width array to detect the magnetic signature of the splice and generate a magnetic image of the splice. In one embodiment, portions of the splice would contain the same embedded magnetic element technology, used in the aforementioned magnetic rip detection application, as well as the magnetic sensor technology can be used to monitor fabric belt splices when the splice is created. The application of this technology would enable a mine friendly and reliable solution to splice monitoring in fabric belt applications. [0023] The one or more embodiments can analyze the length and width of the splice(s).

[0024] It is appreciated that embedded magnetic elements can be one magnetic element used in a splice. It is appreciated that suitable variations of the embedded magnetic elements are contemplated.

[0025] The conveyor system 1 of this invention as shown in FIG. 1 generally includes a pulley system for receiving a pulley engaging under surface 3 of the conveyor belt 2 being monitored, a means for driving the belt along the pulley system, a means for generating a magnetic field or a magnetic array 5, such as permanent magnet or an electro magnet, and a sensor array 6. A tachometer, proximity sensor, encoder and/or the like can be integrated into the conveyor system 1 . Such conveyor belts can be employed in moving coal, rocks, mineral ores (medium) 7 and the like over long distances. In any case, the magnetic array 5 magnetizes embedded magnetic elements within splices of conveyor belt 2.

[0026] The system 1 provides monitoring to both bias and finger splices by changing the embedded element accordingly to monitor the splice across the full width, by capturing the splices control image and monitoring the degradation of the splice over time using distortions in the magnetic image as measured by specific splice parameters, like splice length, splice leading and trailing angles, damages to the magnetic element, shifts in the symmetry of the splice that impacts the magnetic image and splice angle straightness. Here, magnetic elements are added to a fabric belt as it does not have this property naturally.

[0027] A finger splice is a splice where fingers can be formed or cutout from the belt and a splice to interleave fingers from each and facilitate adhesion. One or more layers of the belt repair area and the splice are typically removed. In one example, the splices are triangular shaped. [0028] Typical splices occur at right angles or 90 degrees from the travel direction. A bias splice incorporates an angle or offset angle so that the splice does not run at 90 degrees. Generally, bias splices can mitigate noise and vibration.

[0029] It is appreciated that the splice can include both finger and bias splices/splicing.

[0030] The system 1 includes the magnetic array 5 covering the width of the belt, the array of sensor elements 6 that image the conveyor belt splice as it passes, a tachometer or distance sensor that measures the amount of belt passing, and a control unit or circuitry that process data and alerts the customer to issues. An application uses embedded magnetic element(s) as splice insert(s) that can be installed during a splicing operation.

[0031] Added functionality can be achieved with the addition of ultrasonic sensor to measure the position of the belt edge as the belt passes the array 6, to more accurately know belt position. Added functionality could also be achieved by having RFID tags mark the position of the splice sensors for magnetic splice identification and alignment (synchronization) of the splice to the monitoring system.

[0032] Fig. 2 is a schematic cross-sectional view of an embedded magnetic element or splice insert showing a plurality of splice rip detection wires therein wherein the embedded magnetic element has not been subjected to belt damage.

[0033] Fig. 3 illustrates the magnetic field image of the embedded magnetic element shown in Fig. 2 (without belt damage).

[0034] There are a plurality of magnetically permeable wires within an embedded splice, also referred to as a splice element. These wires are spaced along the longitudinal length of the conveyor belt and/or conveyor belt splices. The splice elements contain a multitude of rip detection wires that are comprised of a magnetically permeable material, such as a ferromagnetic material. For instance, the rip detection wires can be brass plated steel tire cords. [0035] In one example, the embedded splice element wires are steel filaments having a diameter within the range of 0.1 mm to about 0.6 mm. In another example the embedded splice element wires are steel filaments and have a diameter within the range of 0.2 min to 0.4 mm. The filaments can be wound into wire bundles comprising from 2 to about 12 filaments or even about 18.

[0036] The embedded splice element wires can be tire cords having a wide variety of constructions with or without a spiral wrap. Some representative examples of constructions that can be used include 2x, 3x, 4x, 5x, 6x, 7x, 8x, 11 x, 12X, 1 +2, 1 +3, 1 +4, 1+5, 1 +6, 1 +7, 1 +8, 2+1 , 2+2, 2+7, 2+8, 2+9, 2+10, 3+1 , 3+2, 3+3, and 3+9. A more detailed description of steel tire cords containing up to 12 filaments that can be advantageously used as embedded splice element wires in the practice of this invention is provided in U.S. Pat. No. 6,247,514. The teachings of U.S. Pat. No. 6,247,514 are incorporated by reference herein for the purpose of describing suitable steel tire cords that contain up to 12 filaments.

[0037] In one example, the embedded splice element wires are aligned in the embedded magnetic elements at a bias angle a of 15° to 75° from being perpendicular to the longitudinal direction of the belt. The embedded splice element wires are can also be aligned in the embedded magnetic elements at a bias angle a of 30° to 60° and are also aligned in the embedded magnetic elements at a bias angle a of 40° to 50°.

[0038] The embedded splice elements or wires are spaced incrementally across the width of the belt or splice in one example. In another example, individual embedded splice element wires do not extend across more than about 70% of the width of the belt or splice. In some examples, individual embedded splice element wires do not extend across more than about 50% of the width of the belt WW or splice. In another example, individual embedded splice element wires do not extend across more than about 40% or even 30% of the width of the belt WW. In another example, splice elements extend greater than 70% of the width of the belt or splice.

[0039] The embedded splice element wires can vary in length along a line running through the embedded magnetic elements which is perpendicular to the bias angle a, and wherein the shortest rip detection wires have a length L2 which is less than about 50% of the length L1 of the longest rip detection wires in the embedded magnetic elements, as an example. In one example, the shortest embedded splice element wires have a length L2 which is less than about 25% of the length L1 of the longest embedded splice element wires in the embedded magnetic elements. In some cases the shortest embedded splice element wires have a length L2 which is less than about 10% of the length L2 of the longest embedded splice element wires in the embedded magnetic elements.

[0040] Fig. 4 is a diagram illustrating a cross sectional view of a conveyor belt splice 400 in accordance with one or more embodiments. It is appreciated that the splice 400 is provided for illustrative purposes and that suitable variations are contemplated.

[0041] The splice 400 includes a top cover rubber layer, a splice insert material and an inside rubber layer as shown. The top cover rubber layer is substantially thicker than the inside rubber layer.

[0042] The splice insert material has a 6 inch width, in one example.

[0043] The splice 400 is a 15 inch installed in 3/16 inch top cover rubber layer and at a 15 degree bias.

[0044] Fig. 5 is a diagram illustrating a view of a conveyor belt splice insert 500 in accordance with one or more embodiments. It is appreciated that the splice insert 500 is provided for illustrative purposes and that suitable variations are contemplated.

[0045] Figures 6, 7, 8 and 9 show a plurality of example embedded magnetic elements as splice inserts for conveyor belt splices in accordance with one or more embodiments.

[0046] A left side (a) shows the example embedded magnetic elements and/or configuration. A right side (b) shows an example or simulated measured magnetic response. [0047] Fig. 6 is a diagram illustrating a view of a conveyor belt splice inserts for conveyor belt splices in accordance with one or more embodiments. It is appreciated that the view is provided for illustrative purposes and that suitable variations are contemplated.

[0048] 601a is an embedded, biased tire cord as a splice insert(s) 900 near leading and trailing edges of bias splice. Alternatively multiple elements in a multistep splice to provide additional information.

[0049] 601b shows the measured magnetic response.

[0050] 602a is a special 90 degree splice insert(s) 900 with tire cord near leading and trailing edges of bias splice. Alternatively, multiple elements are in a multistep splice to provide additional information.

[0051] 602b shows the measured magnetic response.

[0052] Fig. 7 is a diagram illustrating a view of a conveyor belt splice inserts for conveyor belt splices in accordance with one or more embodiments. It is appreciated that the view is provided for illustrative purposes and that suitable variations are contemplated.

[0053] The splices utilize a plurality of fingers for splicing and splice inserts 500 are configured about the fingers.

[0054] 703a is an embedded, biased tire cord cut with fingers on leading and trailing edges of finger splice in a transition area at end of fingers. Same biased cords.

[0055] 703b shows the measured magnetic response.

[0056] 704a is an embedded, biased tire cord cut with finger pattern near leading and trailing edges of finger splice in transition area at end of fingers. Opposite bias in trailing and leading biases.

[0057] 704b shows the measured magnetic response. [0058] Fig. 8 is a diagram illustrating a view of a conveyor belt splice inserts for conveyor belt splices in accordance with one or more embodiments. It is appreciated that the view is provided for illustrative purposes and that suitable variations are contemplated.

[0059] The splices utilize a plurality of fingers for splicing and splice inserts 500 are configured about the fingers.

[0060] 805a is an embedded, biased tire cord near leading and trailing edges of finger splice in transition area at end of fingers.

[0061] 805b shows the measured magnetic response.

[0062] 806a is an alternative design for finger splice. Could just have a magnetic cable run down the center of the fingers that can then be magnetized to provide polarity images.

[0063] 806b shows example polarity image.

[0064] Fig. 9 is a diagram illustrating a view of a conveyor belt splice inserts for conveyor belt splices in accordance with one or more embodiments. It is appreciated that the view is provided for illustrative purposes and that suitable variations are contemplated.

[0065] 907a is an alternative design for a finger splice that could just have a magnetic cable run along bias of the fingers that can then be magnetized to provide polarity image.

[0066] 907b shows example resulting polarity image.

[0067] 908a is a tire cord placed over the entire splice, but could lose important internal information for splice monitoring. This design may also impact performance of a fabric belt by changing troughability.

[0068] 908b shows the measured magnetic response. [0069] A plurality of example aspects or embodiments are described.

[0070] A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.

[0071] One general aspect includes a system for monitoring conveyor belt splices. The system also includes a splice for a conveyor belt, the splice may include fabric reinforcements and one or more embedded magnetic elements of a splice insert and a pulley engaging surface; a sensor array configured to generate a magnetic image from the one or more embedded magnetic elements of the splice, and circuitry for determining magnetic anomalies generated by structural changes in the splice proximate the one or more embedded magnetic elements.

[0072] Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.

[0073] Implementations may include one or more of the following features. The one or more embedded magnetic elements may include a series of parallel magnetic permeable wires biased such that can be detected and its characteristics measured and monitored from revolution to revolution for change. The the magnetic element may include wires running along the length of the splice in order to capture key splice structural characteristics that could degrade over time and deviations of the magnetic position of these elements indicate a structural change to the splice and potential damage. The system where a change in the splice structural integrity is reflected by positional deviations in the embedded magnetic element and reflected in the magnetic image. The system where the embedded magnetic elements covering a width of the splice. The system where a magnet is configured to magnetize the one or more embedded magnetic elements and generate a magnetic field across a width of the belt. The sensor array configured to monitor a remaining magnetic field across a width of the belt. The splice may include a finger splice. The splice may include a bias splice. The splice only includes fabric reinforcements and omits metal reinforcements. The system where the embedded magnetic elements may include one or more ferromagnetic materials. The system where the embedded magnetic elements may include a plurality of lines formed at an offset angle and formed across a width of the splice. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.

[0074] One general aspect is a conveyor belt that includes an elastomeric body having a load carrying surface and a pulley engaging surface; one or more reinforcement plies disposed within the elastomeric body, a splice includes one or more embedded magnetic elements embedded within the splice structure, a plurality of splice inserts are spaced over a width and length of the splice, the splice insert may include a plurality of magnetically permeable wires as splice detection wires and are aligned with the splice insert, the splice detection wires are aligned at a bias angle of about 15 to 90 degrees from the perpendicular to the longitudinal direction of the belt, the splice detection wires vary in length along a line running through the splice inserts. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.

[0075] Another general aspect includes a method for detecting structural change to a conveyor belt splice. The method also includes advancing a conveyor belt having the conveyor belt splice through a conveyor system, the conveyor belt splice having a splice insert with one or more magnetic elements; generating magnetic images of a magnetic field of the conveyor belt splice, and detecting structural change to the conveyor belt splice based on the generated magnetic images. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. [0076] Implementations may include one or more of the following features. The method may include detecting changes in splice length, splice angularity, splice linearity and splice symmetry. Implementations of the described techniques may include hardware, a method or process, or computer software on a computer-accessible medium.

[0077] The foregoing description of the embodiments has been provided for purposes of illustration and description. Example embodiments are provided so that this disclosure will be sufficiently thorough, and will convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the disclosure, but are not intended to be exhaustive or to limit the disclosure. It will be appreciated that it is within the scope of the disclosure that individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0078] Also, in some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Further, it will be readily apparent to those of skill in the art that in the design, manufacture, and operation of apparatus to achieve that described in the disclosure, variations in apparatus design, construction, condition, erosion of components, gaps between components may present, for example.

[0079] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0080] Spatially relative terms, such as "inner", “adjacent”, "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0081] As used herein, the term “circuitry” may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), and/or memory (shared, dedicated, or group) that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable hardware components that provide the described functionality. In some embodiments, the circuitry may be implemented in, or functions associated with the circuitry may be implemented by, one or more software or firmware modules. In some embodiments, circuitry may include logic, at least partially operable in hardware.

[0082] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.