CONVEYOR SYSTEM

Cross-Reference to Related Application

[001] The present application claims priority from the Australian provisional application No. 2015903084 filed on 3 August 2015, the contents of which is incorporated herein by reference.

Technical Field

[002] The present invention relates to a transponder, transponder assembly, transceiver, monitoring system, method of installation, and kit for obtaining sensor data related to an idler roller of a belt conveyor system.

Background

[003] A breakdown of a belt conveyor system for handling bulk material can be a serious problem. Each minute that the conveyor belt is out of operation can represent substantial economic losses. One particular component of the belt conveyor system which is regularly monitored to avoid unexpected shut down includes the rolling element bearings of the idler rollers.

[004] High operating temperature has been identified as a significant indicator of imminent idler roller ball bearing failure. A common method for monitoring idler roller ball bearing temperature in bulk handling conveyors uses hand-held non-contact thermometers. However, this is extremely time consuming and involves manual input.

[005] An alternative approach to monitoring the idler roller ball bearings is to embed sensors in the conveyor belt to sense the idler roller casing. This approach is disadvantageous as it is requires substantial and uncertain modelling of the thermal transfer of the ball bearing to idler roller casing and then idler roller casing to the conveyor belt. This requirement to model numerous belt conveyor system parameters naturally leads to inaccurate monitoring of the wear of idler rollers.

[006] Therefore, there is a need to alleviate one or more of the above mentioned problems or provide a useful alternative.

[007] 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 acknowledgment or admission or any form of suggestion that the 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.

Summary

[008] In a first aspect there is provided a transponder for generating sensor data related to an idler roller of a belt conveyor system, wherein the transponder is mountable to the idler roller and includes a wireless communication device and a temperature sensor integrated with or coupled to a microcontroller configured to obtain, via the temperature sensor, a temperature measurement indicative of a temperature of a bearing of the idler roller, and transmit, via the wireless communication device, sensor data indicative of the temperature to a transceiver.

[009] In certain embodiments, the sensing device is a passive device which is electrically powered based on a wireless signal received from the transceiver.

[010] In certain embodiments, the sensing device communicates with the transceiver utilising Near Field Communication (NFC).

[011] In certain embodiments, the sensing device includes an accelerometer coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of rotational and low-frequency vibration signals sensed by the accelerometer. [012] In certain embodiments, the transponder includes an acoustic sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of low and high frequency vibration data sensed by the acoustic sensor.

[013] In certain embodiments, the sensing device includes a vibration sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of low and high frequency vibration sensed by the vibration sensor.

[014] In certain embodiments, the transponder has a ring shaped body including a central aperture to receive therethrough a shaft of the idler.

[015] In certain embodiments, the body is a printed circuit board.

[016] In a second aspect there is provided a transponder assembly system including: an adaptor boss configured to retrofittably engage or be secured to a mechanical seal of an idler roller;

a transponder configured according to the first aspect, wherein the transponder is secured to the adaptor boss; and

a dust cover to retrofittably secure to the idler roller to cover the transponder and adaptor boss.

[017] In certain embodiments, the transponder includes a printed circuit board which includes a central aperture to receive therethrough a shaft of the idler roller.

[018] In certain embodiments, the cover includes a central aperture to receive therethrough the shaft of the idler roller.

[019] In certain embodiments, the mechanical seal is a labyrinth seal of the idler roller. [020] In certain embodiments, the adaptor boss and transponder rotate together with a roller element of the idler roller and under the cover which is stationary relative to the roller element.

[021] In a third aspect there is provided a transceiver for receiving sensor data related to an idler roller of a belt conveyor system, wherein the transceiver is mountable to a bracket of the idler roller, including a wireless communication device and a data bus transceiver integrated with or coupled to a microcontroller configured to:

receive, via the wireless communication device, sensor data transmitted by a transponder mountable to the idler roller;

process the sensor data to determine if an alert condition has been satisfied;

in response to the alert condition being satisfied, transfer, via the data bus transceiver of the microcontroller to a diagnostic processing system, at least one of:

an alert; and

at least some of the sensor data.

[022] In certain embodiments, the transceiver is an active device configured to transmit a wireless signal to the transponder which is a passive device, wherein the wireless signal electrically powers the transponder to transmit the sensor data to the transceiver.

[023] In a fourth aspect there is provided a monitoring system for obtaining sensor data related to an idler of a belt conveyor system, wherein the monitoring system includes: a transponder configured according to the first aspect; and

a transceiver configured according to the third aspect.

[024] In certain embodiments, the monitoring system includes a plurality of transponders and a plurality of transceivers.

[025] In a fifth aspect there is provided a monitoring system for obtaining sensor data related to an idler of a belt conveyor system, wherein the monitoring system includes: a transponder assembly system configured according to the second aspect; and a transceiver configured according to the third aspect.

[026] In certain embodiments, the monitoring system includes a plurality of transponder assembly systems and a plurality of transceivers.

[027] In a sixth aspect there is provided a belt conveyor system including:

a plurality of idler rollers supporting a conveyor belt, each idler roller having an associated bracket; and

a monitoring system configured according to the fourth or fifth aspect

[028] In a seventh aspect there is provided a method of installing a monitoring system to an idler roller, wherein the monitoring system is configured according to the fifth aspect, wherein the method includes:

removing an end cap of the idler roller;

mounting the adaptor boss to a mechanical seal of the idler roller;

securing the transponder to a mounting surface of the adaptor boss;

mounting the cover to an end cap engagement assembly of the idler roller;

mounting the transceiver to a bracket of the idler; and

connecting the transceiver to a data link to communicate with a diagnostic processing system.

[029] In an eighth aspect there is provided a kit for obtaining sensor data related to an idler of a belt conveyor system, wherein the kit includes:

a transponder assembly system configured according to the second aspect; and a transceiver configured according to the third aspect.

[030] In a ninth aspect there is provided a transponder for generating sensor data related to an idler roller of a belt conveyor system, wherein the transponder is mountable to the idler roller and includes a wireless communication device and a temperature sensor integrated with or coupled to a microcontroller configured to obtain, via the temperature sensor, a temperature measurement indicative of a temperature of a bearing of the idler roller, and transmit, via the wireless communication device, sensor data indicative of the temperature to a transceiver.

[031] In certain embodiments, the sensing device is a passive device which is electrically powered based on a wireless signal received from the transceiver which is an active device.

[032] In certain embodiments, the sensing device communicates with the transceiver utilising Near Field Communication (NFC).

[033] In certain embodiments, the sensing device includes an accelerometer coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of rotational and/or vibration signals sensed by the accelerometer.

[034] In certain embodiments, the transponder includes an acoustic sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of acoustic signals sensed by the acoustic sensor.

[035] In certain embodiments, the sensing device includes a vibration sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of vibration sensed by the vibration sensor.

[036] In certain embodiments, the transponder has a ring shaped body including a central aperture to receive therethrough a shaft of the idler roller.

[037] In certain embodiments, the body is a circuit board.

[038] In a tenth aspect there is provided a transponder assembly including:

an adaptor boss configured to retrofittably engage or be secured to a mechanical seal of an idler roller; and a transponder configured according to the ninth aspect, wherein the transponder is secured to the adaptor boss.

[039] In certain embodiments, the mechanical seal is a labyrinth seal of the idler roller.

[040] In certain embodiments, the adaptor boss and transponder rotate together with a roller element of the idler roller.

[041] In an eleventh aspect there is provided a monitoring system for obtaining sensor data related to an idler roller of a belt conveyor system, wherein the monitoring system includes:

a transponder configured according to the ninth aspect; and

the transceiver including a second wireless communication device and a data bus transceiver integrated with or coupled to a second microcontroller configured to:

receive, via the second wireless communication device, the sensor data transmitted by the transponder;

process the sensor data to determine if an alert condition has been satisfied; in response to the alert condition being satisfied, transfer, via the data bus transceiver of the microcontroller to a diagnostic processing system, at least one of:

an alert; and

at least some of the sensor data.

[042] In certain embodiments, the monitoring system includes a plurality of transponders and a plurality of transceivers.

[043] In a twelfth aspect there is provided a monitoring system for obtaining sensor data related to an idler roller of a belt conveyor system, wherein the monitoring system includes:

a transponder assembly configured according to the tenth aspect; and

the transceiver including a second wireless communication device and a data bus transceiver integrated with or coupled to a second microcontroller configured to: receive, via the second wireless communication device, the sensor data transmitted by the transponder;

process the sensor data to determine if an alert condition has been satisfied; in response to the alert condition being satisfied, transfer, via the data bus transceiver of the second microcontroller to a diagnostic processing system, at least one of:

an alert; and

at least some of the sensor data.

[044] In certain embodiments, the monitoring system includes a dust cover to retrofittably secure to the idler roller to cover the transponder and the adaptor boss.

[045] In certain embodiments, the cover includes a central aperture.

[046] In certain embodiments, the transceiver, or a portion thereof, is mounted to the dust cover.

[047] In certain embodiments, the monitoring system includes a plurality of transponder assemblies and a plurality of transceivers.

[048] In a thirteenth aspect there is provided a belt conveyor system including:

a plurality of idler rollers supporting a conveyor belt; and

a monitoring system configured according to the twelfth aspect.

[049] In a fourteenth aspect there is provided a method of installing a monitoring system to an idler roller, wherein the monitoring system is configured according to the thirteenth aspect, wherein the method includes:

removing an end cap of the idler roller;

mounting the adaptor boss to a mechanical seal of the idler roller;

securing the transponder to a mounting surface of the adaptor boss;

mounting the transceiver relative to the transponder; and connecting the transceiver to a data link to communicate with a diagnostic processing system.

[050] In certain embodiments, the method includes mounting the transceiver to a bracket of the idler roller.

[051] In certain embodiments, the method includes mounting a dust cover to an end cap engagement assembly of the idler roller.

[052] In certain embodiments, at least a portion of the transceiver is mounted to a dust cover, wherein the step of mounting the transceiver is performed, or at least partially performed, by mounting the dust cover to an end cap engagement assembly of the idler roller.

[053] In a fifteenth aspect there is provided a kit for obtaining sensor data related to an idler roller of a belt conveyor system, wherein the kit includes:

a transponder assembly configured according to the tenth aspect; and

a transceiver including a second wireless communication device and a data bus transceiver integrated with or coupled to a second microcontroller configured to:

receive, via the second wireless communication device, the sensor data transmitted by the transponder;

process the sensor data to determine if an alert condition has been satisfied; in response to the alert condition being satisfied, transfer, via the data bus transceiver of the microcontroller to a diagnostic processing system, at least one of:

an alert; and

at least some of the sensor data.

[054] In certain embodiments, the kit includes a dust cover retrofittably securable to the idler roller to cover the transponder and the adaptor boss.

[055] In certain embodiments, the cover includes a central aperture. [056] In certain embodiments, the adaptor boss and transponder are able rotate together under the cover when mounted.

[057] In certain embodiments, the transceiver is mountable to a bracket of the idler roller.

[058] In certain embodiments, the transceiver, or a portion thereof, is mounted to the dust cover.

[059] Further and other aspects and embodiments will be appreciated throughout the detailed description of the preferred embodiments.

Brief Description of the Figures

[060] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying figures.

[061] Figure 1 is a cross-sectional view of an idler roller of a belt conveyor system including a pair of transponders and transceivers;

[062] Figure 2A is a magnified cross-sectional view of Section A of one end of the idler roller of Figure 1 showing a transponder and transceiver;

[063] Figure 2B is a magnified cross-sectional view of an alternate arrangement of the transponder and the transceiver for an end of an idler roller;

[064] Figure 3 is a block diagram representing the magnetically coupled link between the transponder and the transceiver;

[065] Figure 4A is a functional block diagram representing a further example of the elements of the transponder; [066] Figure 4B is a functional block diagram representing a further example of the elements of the transceiver;

[067] Figure 4C is a functional block diagram representing a further example of the elements of transponder;

[068] Figure 4D is a functional block diagram representing a further example of the elements of the transponder;

[069] Figure 5 is a block diagram representing an example system including a plurality of transponder and transceiver pairs for obtaining sensor data for a plurality of idler rollers of a belt conveyor system;

[070] Figure 6A illustrates a an end view of an example of the transponder assembly mounted to the idler roller;

[071] Figure 6B illustrates an exploded end view of the transponder assembly of Figure 6A;

[072] Figure 6C illustrates a cross-sectional end view of the transponder assembly mounted to the idler roller in Figure 6 A;

[073] Figure 6D illustrates a cross-section end view of an alternate example of the transponder assembly mounted to the idler roller; and

[074] Figure 7 is a flow chart representing an example method for a retrofittable installation of a transponder and reader/transceiver pair to an idler roller.

Detailed Description of the Preferred Embodiments

[075] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments. In the figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the figures.

[076] Referring to Figures 1, 2A and 2B there is shown an example embodiment of the present invention in use with an idler roller 10 of a belt conveyor system 20. The example embodiment includes a transponder 40 and a transceiver 50 which together form a monitoring system 30. The transceiver 50 can be provided in the form of a reader device.

[077] The transponder 40 is configured to be retrofittably mounted to an end of the idler roller 10. The transceiver 50 is configured to be mounted to a bracket supporting the idler roller 10. The transponder 40 is configured to receive a radio signal from the transceiver 50, sense a temperature of a bearing 380 of the respective end of the idler roller 10 and transmit the sensed temperature to the transceiver 50. Wireless communication between the transceiver 50 and the transmitter 40 utilises near field communications (NFC). As will be explained in further detail below, the transponder 40 can be retrofittably mounted to a mechanical seal of the idler roller 10 such that it can be installed to existing idler rollers 10 in use.

[078] Referring to Figure 3, the transponder 40 includes a first wireless communication device 60 and a temperature sensor 70 integrated with or coupled to a first microcontroller 80. As shown in Figure 5, in response to the transponder 40 receiving a read signal 450 from the transceiver 50, the first microcontroller 80 is configured to obtain, via the temperature sensor 70, a temperature measurement indicative of a temperature of the bearing 380 of the idler roller 10. The first microcontroller 80 then transmits, via the first wireless communication device 60, sensor data 460 indicative of the sensed temperature to the transceiver 50.

[079] Still referring to Figure 3, the transceiver 50 includes a second wireless communication device 120 and a data bus transceiver 310 integrated with or coupled to a second microcontroller 130. As shown in Figure 5, the second microcontroller 130 is configured to receive, via the second wireless communication device 120, the sensor data 460 from the transponder 40 and transfer, via the data bus transceiver 310, an alert 470 and/or at least some of the sensor data 460 to a diagnostic processing system 150 executing diagnostic software 440.

[080] The transponder 40 is preferably a passive device and the transceiver 50 is an active device electrically powered by an electrical power source 160. More specifically, antenna of the first wireless communication device 60 and antenna of the second wireless communication device 120 are loosely coupled together to form a transformer as shown in Figure 3. The transponder 40 is configured to be electrically powered by receiving, via the first wireless communication device 60, the read signal 450 transmitted by the transceiver 50 via the second wireless communication device 120. As previously mentioned, communication between the transponder 50 and the transceiver 40 utilise Near Field Communication (NFC). Advantageously, due to the transponder 40 operating as a passive device, the transponder 40 does not need to have a portable electrical power source replaced over time after installation. Each transceiver and transponder pair 50, 40 can be separated by up to ten centimetres in order to achieve acceptable wireless data communication therebetween.

[081] As shown in Figure 4A, the first microcontroller 80 of the transponder 40 includes a processor 170, a memory 180, and an input/output interface 190 coupled together via a bus 200. The memory 180 can include non-volatile memory 210 and volatile memory 220. The first microcontroller 80 can also have integrated therewith the temperature sensor 70. However, in other arrangements, the temperature sensor 70 may be provided in the form of a temperature probe 230 which is coupled to the first microcontroller 80 via the input/output interface 190. The temperature probe 230 can be utilised in situations where substantially direct or near-direct temperature sensing of the bearing of the idler roller 10 is possible or required. The non-volatile memory 210 can have stored therein a computer program embodied in the form of executable instructions 240 for executing commands and generating sensor data 460 based on the sensor measurements received from the one or more sensors. [082] As shown in Figure 4B, the second microcontroller 130 of the transceiver 50 includes a processor 250, a memory 260, an input/output interface 270 coupled together via a bus 280. The memory 260 can include non- volatile memory 290 and volatile memory 300. The input/output interface 270 of the second microcontroller 130 is coupled to the first wireless communication device 60 and a data bus transceiver 310.

[083] The data bus transceiver 310 of the transceiver 50 is configured to communicate with the diagnostic processing system 150 via a physical data link 320. As shown in Figure 5, multiple transceiver and transponder pairs 50, 40 may be installed for a belt conveyor system 20, wherein data transferred to the diagnostic processing system 150 can be via one or more data aggregation devices/communications hubs 340. The data link 320 from each transceiver 50 could be for example an RS484 cable, a contact closure, or a proprietary system like Austdac's Dupline™.

[084] Referring to Figure 4B, the non- volatile memory 290 of the second microcontroller 130 can have stored therein a computer program embodied in the form of executable instructions 330 for generating one or more commands to be transmitted to the transponder 40. In one form the executable instructions 330 can configure the second microcontroller 130 to transfer a wireless signal 450 indicating a request to obtain sensor data 460 in relation to the bearing of the respective end of the idler roller 10. For example, the executable instructions 330 can configure the second microcontroller 130 to periodically transmit a wireless signal 450 indicative of a command requesting a temperature reading from the transponder 40, so as to obtain periodic sensor measurements over time.

[085] In response to the transceiver 50 receiving the sensor data 460 from the transponder 40, the processor 250 of the second microcontroller 130 is configured to determine whether the sensor data 460 satisfies an alert condition. For example, the alert condition may be a comparison of the sensed temperature against a threshold temperature stored in non-volatile memory 290 of the second microcontroller 130. In the event of a positive comparison, for example where the sensed temperature is equal to or greater than the threshold temperature, the alert 470 and/or the sensor data 460 is transferred to the diagnostic processing system 150. In configurations where only the alert 470 is transferred,, an efficient use of network bandwidth is achieved because only exceptions are transferred to the diagnostic processing system 150 rather than all the collected sensor data 460.

[086] Referring to Figure 4C there is shown a further variation on another example of the transponder 40. Like reference numerals are used to identify like parts between Figures 4 A and 4C. In particular, the transponder 40 includes an accelerometer 360 coupled to or integrated with the first microcontroller 80. In this configuration, at least some of the sensor data 460 generated by the transponder 40 is indicative of rotational and/or vibration sensed by the accelerometer. In certain embodiments, the vibration sensed is low frequency vibration. The sensor data 460 can be indicative of the vibration being experienced by the idler roller 10 which can be an early warning sign of an upcoming fault of the bearing 380 of the idler roller 10. The transponder 40 may only generate sensor data 460 indicative of the rotational and low-frequency vibration signals in response to receiving a command from the transceiver 50 to provide acceleration data. In response to the transceiver 50 receiving the sensor data 460 indicative of the rotational and low- frequency vibration signals, the processor 250 of the second microcontroller 130 is configured to determine whether the sensor data 460 satisfies an alert condition.

[087] Referring to Figure 4D there is shown a further variation of the transponder. Like reference numerals are used to identify like parts between Figures 4A, 4C and 4D. In particular, the transponder 50 includes a vibration sensor 370 and an acoustic sensor 390 coupled to or integrated with the first microcontroller 80. The vibration sensor 370 and the acoustic sensor 390 can be configured to sense vibration such as low and high frequency vibration. The transponder 40 may generate sensor data indicative of the vibration in response to receiving a command from the transceiver 50 to provide such data. In response to the transceiver 50 receiving the sensor data 460 indicative of the vibration sensed by the vibration sensor 370 and/or the acoustic sensor 390, the vibration data can be processed by the second microcontroller 130 of the transceiver 50 to determine if an alert condition has been satisfied.

[088] In particular configurations, a series of discrete sensor measurements can be obtained over a period of time by the transponder 40 and transferred to the transceiver 50. In particular, a command can be transmitted by the transceiver 50 to the transponder 40, wherein the command is indicative of a request for a series of discrete sensor measurements for a predetermined period of time. For example, the series of discrete sensor measurements may be obtained every second for a one minute period. The command may also indicative of a selection of the one or more sensors 70, 230, 360, 370, 390 of a sensor array 350 for generating the series of discrete sensor measurements. In order to electrically power the transponder 40 during the time period, the transceiver 50 may transmit only a carrier wave in order to electrically power the transponder 40 to obtain the series of discrete sensor measurements from the one or more sensors of the sensor array 350.

[089] Referring to Figures 6A, 6B and 6C there is shown an example of a transponder assembly 601. The transponder assembly 601 includes the transponder 40 embodied on a ring shaped circuit board such as a ring shaped printed circuit board 630 and an adaptor boss 620. The ring shaped body of the printed circuit board 630 includes an aperture 631 which receives therethrough the shaft 110 of the idler roller 10. The printed circuit board 630 can be mounted to the idler roller 10 via an adaptor boss 620 which retrofittably engages a mechanical seal 12 of the idler roller 10, such as the labyrinth seal. The adaptor boss 620 includes an engagement portion 621 which is inserted into and engages with the mechanical seal 12 by way of interference fit or is secured in place by an adhesive. The printed circuit board 630 can be secured to a mounting surface 622 of the adaptor boss 620 via adhesive or the like. A dust cover 610 provided in the form of an oversized retro-fit dust cover 610 can then be fitted over the printed circuit board 630, wherein an engagement portion 611 of the dust cover 610 engages with the end cap engagement assembly of the idler roller 10 such as to protect the printed circuit board 630 as shown in Figure 6A. The dust cover 610 together with the transponder 40 and the adaptor boss 620 define a transponder assembly system. The dust cover 610 also includes a central aperture 612 to receive therethrough the shaft 110 of the idler roller 10. The cover portion 613 of the dust cover 610 is clear of the roller element 11 of the idler roller 10. In this configuration, the transponder 40 embodied on the ring shaped printed circuit board 630 and adaptor boss 620 rotate together with the roller element 11 of the idler roller 10. The dust cover remains stationary relative to the roller element 11 of the idler roller 10.

[090] Due to the transponder 40 being mounted within close proximity to the bearing of the idler roller 10, a highly accurate temperature measurement can be obtained. The temperature sensor 70 of the transponder 40 can be located adjacent to the casing of the bearing to accurately sense the temperature of the bearing. As shown in Figure 6C, the transponder 40 includes a temperature probe 230 which can directly contact or be located substantially proximate the bearing casing to obtain a highly accurate temperature measurement.

[091] As shown in Figures 1 and 2A, the transceiver 50 can be mounted to a bracket 100 of the idler roller 10. In one form, the transceiver 50 can be adhesively secured or fastened using one or more fasteners to the bracket 100 although other securing arrangements are possible. It is possible for the transceiver 50 to be secured on an inner surface of the bracket relative to the sensing device 40 as shown in Figures 1 and 2A. However, in certain idler roller configurations, there may be insufficient space for the transceiver 50 and the transponder 40 to both be located within the gap between the end of the idler roller 10 and the bracket 100. Therefore, for idler roller configuration with an insufficient gap, the transceiver 50 can be mounted to the rear surface of the bracket 100 as shown in Figure 2B. It will be appreciated that it is preferable to install the transponder 40 and the transceiver 50 in co-alignment so as to promote successful wireless communication therebetween.

[092] In an alternate configuration as shown in Figure 6D, the transceiver 50, or a portion thereof, can be mounted to the dust cover 610. In particular, the electronics 690 of the transceiver 50 can be secured to an inner surface of the dust cover 610. As such, the mounting of the dust cover 610 to the end cap engagement assembly also simultaneously mounts the transceiver 50, or a portion thereof, relative to the transponder 40 such that wireless communication is possible therebetween. In this arrangement, the dust cover 610 covers the transponder 40, the adaptor boss 620 and the transceiver 50. A data transfer medium, such as one or more electrical wires or data cables can extend from the external face of the cover 610 and couple to one of the one or more data aggregation devices/communications hubs 340. It will be appreciated that due to the cover 610 being stationary relative to the rotating roller element 11 during operation, the transceiver is also stationary relative to the rotating roller element 11 during operation.

[093] In certain arrangements, only a portion of the transceiver 50 may be mounted to and located under the dust cover 610. In particular, in some circumstances it may be convenient that a portion of the transceiver 50, such as the data bus transceiver 310, be located external to the dust cover 610. Therefore, the data transfer medium, such as one or more electrical wires, data cables or the like, may extend from the second microcontroller 130 via the cover 610 and connect to the data bus transceiver 310.

[094] It will be appreciated that a transponder 40 and transceiver 50 pair can be installed at opposing ends of an idler roller 10 to thereby obtain sensor data 460 for both bearings 380 at opposing ends of the idler roller 10. As shown in Figure 5, a plurality of transponder and transceiver pairs 40, 50 may be retrofittably installed to a plurality of idler rollers 10 of the conveyer belt system 20 to thereby obtain sensor data 460 for at least some or all idler rollers 10 of the belt conveyor system 20.

[095] Referring to Figure 7 there is shown a flow chart representing a method 700 for installing the system 30 for obtaining sensor data 460 related to an idler roller 10 of a conveyor belt system 20. In particular, at step 710 the method 700 includes removing an end cap from an end cap engagement assembly of the idler roller 10, thereby exposing the mechanical seal 12. At step 720, the method 700 includes mounting the adaptor boss 620 to the mechanical seal 12 of the idler roller 10. At step 730, the method 700 includes mounting the transponder 40 to the mounting surface 622 of the adaptor boss 620. At step 740 the method 700 includes mounting the transceiver 50 relative to the transponder 40. At step 760, the method 700 includes connecting the transceiver 50 to the data link 320 used for communicating with the diagnostic processing system 150.

[096] As explained above, in certain embodiments, the method 700 includes mounting the transceiver 50 to the bracket 100 that supports the idler roller 10. A dust cover 610 can be mounted over the transponder 40 which engages with the end cap engagement assembly of the idler 10.

[097] In alternate embodiments, the transceiver 50, or at least a portion of the transceiver 50, is mounted to the dust cover 610. In this arrangement, the mounting of the dust cover 610 which engages with the end cap engagement assembly of the idler 10 results in also mounting the transceiver 50, or a portion thereof, relative to the transponder 40.

[098] It will be appreciated that method 700 can be repeated for each end of the idler roller 10 so that both bearings 380 of the idler roller 10 can be monitored. It will also be appreciated that the method 700 can be repeated for multiple idler rollers 10 of the belt conveyor system 20.

[099] A kit can be provided for retrofitting a monitoring system 30 to an idler roller 10 for obtaining sensor data 460 related to the idler roller 10. In particular, the kit includes at least one transponder 40 and at least one transceiver 50. The kit can also include a plurality of adaptor bosses 620 for retrofittable mounting to different sized mechanical seals of different idler rollers 10. In particular, each adaptor boss 620 includes a differently sized engagement portion 621 to engage differently sized mechanical seals 12 for various idler rollers 10. Therefore, an appropriately sized adaptor boss 620 can be selected by the installer from the kit for the specific idler roller 10. The kit also includes at least one dust cover 610. In the event that the kit includes a plurality of transponder 40 and transceivers 50, the kit can include a plurality of dust covers 610. As explained above, in certain embodiments, the transceiver 50, or at least a portion thereof, is mounted to the dust cover 610. In alternate embodiments, the transceiver 50 can be mounted to the bracket 100 that supports the idler roller 10. The kit may also include one or more fasteners and/or an adhesive to mount the transceiver 50 to the bracket 100 and/or the transponder 40 to the mounting surface 622 of the adaptor boss 620.

[0100] In one variation, in order to optimise the coupling between the transponder 40 and transceiver 50 a suitably low frequency can be chosen for the wireless communication, although it will be appreciated that this is not essential. The suitably low frequency can assist with minimising eddy currents and enabling the shaft 110 to concentrate the flux across the link. If the transponder 40 and transceiver 50 are centred accurately around the axis of the shaft 110 then the coupling coefficient between coils of the transponder 40 and transceiver 50 will be independent of the rotation between both components.

[0101] Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention.

[0102] Further aspects and embodiments of the present invention can be found in the following numbered clauses

Clause 1. A transponder for generating sensor data related to an idler roller of a belt conveyor system, wherein the transponder is mountable to the idler roller and includes a wireless communication device and a temperature sensor integrated with or coupled to a microcontroller configured to obtain, via the temperature sensor, a temperature measurement indicative of a temperature of a bearing of the idler roller, and transmit, via the wireless communication device, sensor data indicative of the temperature to a transceiver.

Clause 2. The transponder according to clause 1, wherein the sensing device is a passive device which is electrically powered based on a wireless signal received from the transceiver.

Clause 3. The transponder according to clause 2, wherein the sensing device communicates with the transceiver utilising Near Field Communication (NFC). Clause 4. The transponder according to any one of clauses 1 to 3, wherein the sensing device includes an accelerometer coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of rotational and low-frequency vibration signals sensed by the accelerometer sensed by the accelerometer.

Clause 5. The transponder according to any one of clauses 1 to 4, wherein the transponder includes an acoustic sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of low and high frequency data sensed by the acoustic sensor.

Clause 6. The transponder according to any one of clauses 1 to 5, wherein the sensing device includes a vibration sensor coupled to the microcontroller, wherein at least some of the sensor data transmitted to the transceiver is indicative of low and high frequency vibration data sensed by the vibration sensor.

Clause 7. The transponder according to any one of clauses 1 to 6, wherein the transponder has a ring shaped body including a central aperture to receive therethrough a shaft of the idler.

Clause 8. The transponder according to clause 7, wherein the body is a printed circuit board.

Clause 9. A transponder assembly system including:

an adaptor boss configured to retrofittably engage or be secured to a mechanical seal of an idler roller;

a transponder configured according to any one of clauses 1 to 8, wherein the transponder is secured to the adaptor boss; and

a dust cover to retrofittably secure to the idler roller to cover the transponder and adaptor boss. Clause 10. The transponder assembly system according to clause 9, wherein the transponder includes a printed circuit board which includes a central aperture to receive therethrough a shaft of the idler roller.

Clause 11. The transponder assembly system according to clause 10, wherein the cover includes a central aperture to receive therethrough the shaft of the idler roller.

Clause 12. The transponder assembly system according to any one of clauses 9 to 11, wherein the mechanical seal is a labyrinth seal of the idler roller.

Clause 13. The transponder assembly system according to any one of clauses 9 to 12, wherein the adaptor boss and transponder rotate together with a roller element of the idler roller and under the cover which is stationary relative to the roller element.

Clause 14. A transceiver for receiving sensor data related to an idler roller of a belt conveyor system, wherein the transceiver is mountable to a bracket of the idler roller, including a wireless communication device and a data bus transceiver integrated with or coupled to a microcontroller configured to:

receive, via the wireless communication device, sensor data transmitted by a transponder mountable to the idler roller;

process the sensor data to determine if an alert condition has been satisfied;

in response to the alert condition being satisfied, transfer, via the data bus transceiver of the microcontroller to a diagnostic processing system, at least one of:

an alert; and

at least some of the sensor data.

Clause 15. The transceiver according to clause 11, wherein the transceiver is an active device configured to transmit a wireless signal to the transponder which is a passive device, wherein the wireless signal electrically powers the transponder to transmit the sensor data to the transceiver. Clause 16. A monitoring system for obtaining sensor data related to an idler of a belt conveyor system, wherein the monitoring system includes:

a transponder configured according to any one of clauses 1 to 8; and

a transceiver configured according to any one of clauses 14 or 15.

Clause 17. The monitoring system according to clause 16, wherein the monitoring system includes a plurality of transponders and a plurality of transceivers.

Clause 18. A monitoring system for obtaining sensor data related to an idler of a belt conveyor system, wherein the monitoring system includes:

a transponder assembly system configured according to any one of clauses 9 to 13; and

a transceiver configured according to any one of clause 14 or 15.

Clause 19. The monitoring system according to clause 18, wherein the monitoring system includes a plurality of transponder assemblies and a plurality of transceivers.

Clause 20. A belt conveyor system including:

a plurality of idler rollers supporting a conveyor belt, each idler roller having an associated bracket;

a monitoring system configured according to any one of clauses 16 to 19

Clause 21. A method of installing a monitoring system to an idler roller, wherein the monitoring system is configured according to clause 18, wherein the method includes: removing an end cap of the idler roller;

mounting the adaptor boss to a mechanical seal of the idler roller;

securing the transponder to a mounting surface of the adaptor boss;

mounting the dust cover to an end cap engagement assembly of the idler roller; mounting the transceiver to a bracket of the idler; and

connecting the transceiver to a data link to communicate with a diagnostic processing system. Clause 22. A kit for obtaining sensor data related to an idler of a belt conveyor system, wherein the kit includes:

a transponder assembly system configured according to any one of clauses 9 to 13; and

a transceiver configured according to clause 14 or 15.