Conveyor Condition Monitor For A Conveyor With Linked Trollies

Abstract

A conveyor condition monitor, for use with a conveyor comprising a plurality of trollies running along a conveyor rail and linked to one another by a chain link system, is disclosed. The monitor comprises a conveyor monitoring station and a first deformation sensor. The deformation sensor is in communication with the conveyor monitor, and is adapted to notify the conveyor monitor of the presence of a deformed trolley in the conveyor.

1 . A conveyor condition monitor coupled to a conveyor, the conveyor comprising a plurality of trollies running along a conveyor rail and linked to one another by a chain link system, the conveyor condition monitor comprising:
 a conveyor monitoring station; and   a deformation sensor comprising an ultrasonic sensor configured to transmit waves at ultrasonic frequencies and receive waves at ultrasonic frequencies,   wherein the deformation sensor is in communication with the conveyor monitoring station, wherein the deformation sensor is configured to detect a deformed trolley among the plurality of trollies based on the waves received by the ultrasonic sensor, and wherein the deformation sensor is configured to notify the conveyor monitoring station of the presence of the deformed trolley in the conveyor.   
     
     
         2 . The conveyor condition monitor as claimed in  claim 1 , wherein the deformation sensor is configured to have a first state and a second state, the first state indicating that a trolley, among the plurality of trollies, is not deformed and the second state indicating that the trolley is deformed. 
     
     
         3 . The conveyor condition monitor as claimed as  claim 1 , wherein the ultrasonic sensor comprises a first ultrasonic transceiver arranged along with the conveyor monitoring station on one side of the conveyor trollies and a second ultrasonic transceiver arranged on the opposite side of the conveyor trollies. 
     
     
         4 . The conveyor condition monitor as claimed in  claim 3 , wherein, in a first state, the ultrasonic waves emitted by the ultrasonic transceivers are uninterrupted, in a second state, the ultrasonic waves emitted by the ultrasonic transceivers are interrupted, the first state indicating that a trolley, among the plurality of trollies, is not deformed, and the second state indicating that the trolley is deformed. 
     
     
         5 . The conveyor condition monitor as claimed in  claim 4 , wherein a strength of a reflected signal or a time of flight of the reflected signal is used to determine if the ultrasonic waves are interrupted. 
     
     
         6 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the deformation sensor and the second deformation sensor are arranged so as to be positionable symmetrically about the conveyor rail. 
     
     
         7 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor is configured to have a first state and a second state, the first state indicating that a trolley is not deformed and the second state indicating that the trolley is deformed. 
     
     
         8 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor comprises an optical sensor, wherein the optical sensor is arranged such that when a trolley is in the second state it interrupts a light beam. 
     
     
         9 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor comprises a mechanical sensor, wherein in a first state, the mechanical sensor is undeflected, and in a second state the mechanical sensor is deflected, the first state indicating that a trolley is not deformed and the second state indicating that the trolley is deformed. 
     
     
         10 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor comprises an electrical circuit, wherein in a first state, the electrical circuit is unbroken, and in a second state the electrical circuit is broken, the first state indicating that a trolley is not deformed and the second state indicating that the trolley is deformed. 
     
     
         11 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor comprises a magnetic field, wherein in a first state, the magnetic field is continuous, and in a second state the magnetic field is interrupted, the first state indicating that a trolley is not deformed and the second state indicating that the trolley is deformed. 
     
     
         12 . The conveyor condition monitor as claimed in  claim 1 , further comprising a second deformation sensor, wherein the second deformation sensor comprises a harmonic sensor, and wherein the harmonic sensor is configured to detect vibrations of wheels of a trolley, among the plurality of trollies. 
     
     
         13 . The conveyor condition monitor as claimed in  claim 12 , wherein in a first state, vibrations of the wheels of a trolley are present, and in a second state the vibrations of the wheels of a trolley are reduced, the first state indicating that a trolley is not deformed and the second state indicating that the trolley is deformed. 
     
     
         14 . The conveyor condition monitor as claimed in  claim 13 , wherein when the trolley is deformed, a trolley wheel is bent, stationary or missing. 
     
     
         15 . The conveyor condition monitor as claimed in  claim 1 , further comprising a marking device configured to mark an individual trolley in the conveyor. 
     
     
         16 . The conveyor condition monitor as claimed in  claim 15 , wherein the marking device is in communication with the deformation sensor, and wherein the marking device is configured to mark the deformed trolley in the conveyor. 
     
     
         17 . The conveyor condition monitor as claimed in  claim 1 , further comprising a notification device configured to send a notification indicating the presence of the deformed trolley in the conveyor. 
     
     
         18 . The conveyor condition monitor as claimed in  claim 17 , wherein the notification includes:
 a unique identifier for the trolley; and   the position of the trolley in the conveyor.   
     
     
         19 . A conveyor condition monitor coupled to a conveyor, the conveyor comprising a plurality of trollies running along a conveyor rail and linked to one another by a chain link system, the conveyor condition monitor comprising:
 a conveyor monitoring station; and   a deformation sensor comprising a magnetic field, wherein the deformation sensor is in communication with the conveyor monitoring station, wherein the deformation sensor is configured to detect a deformed trolley among the plurality of trollies based on whether the magnetic field is continuous or interrupted, and wherein the deformation sensor is configured to notify the conveyor monitoring station of the presence of the deformed trolley in the conveyor.   
     
     
         20 . The conveyor condition monitor as claimed in  claim 19 , wherein the deformation sensor is configured to have a first state and a second state, wherein in the first state, the magnetic field is continuous and the first state indicating that a trolley, among the plurality of trollies, is not deformed, and wherein, in the second state, the magnetic field is interrupted and the second state indicating that the trolley is deformed.