Sensor systems and methods for detecting conveyor tension in a mining system

Abstract

A conveyor system that includes a sprocket, a conveyor element, a sensor, a tensioning system, and an electronic processor. The conveyor element is coupled to the sprocket to move around the sprocket. The sensor is positioned adjacent to the sprocket and configured to generate an output signal indicative of a detection of the conveyor element. The electronic processor is coupled to the sensor and to the tensioning system. The electronic processor is configured to receive the output signal from the sensor, estimate a trajectory of the conveyor element based on the output signal, determine a value for slack distance based on the estimated trajectory of the conveyor element, and control the tensioning system based on the value for slack distance.

1 . A conveyor system, comprising:
 a sprocket;   a conveyor element of a conveyor, the conveyor element coupled to the sprocket to move around the sprocket;   a flightbar of the conveyor supported by the conveyor element and moves with the conveyor element;   a sensor positioned adjacent the sprocket and configured to generate an output signal indicating a position of the flightbar;   a tensioning system; and   an electronic processor coupled to the sensor and the tensioning system, the electronic processor configured to
 receive the output signal from the sensor, 
 determine a tension state of the conveyor based on the output signal, and 
 control the tensioning system based on the tension state to change a tension of the conveyor element. 
   
     
     
         2 . The conveyor system of  claim 1 , wherein the sensor is a binary proximity sensor, and wherein the sensor is positioned corresponding to a slack distance of the conveyor element. 
     
     
         3 . The conveyor system of  claim 1 , further comprising:
 a second sensor positioned adjacent the sprocket and configured to generate a second output signal indicating the position of the flightbar, the second sensor positioned corresponding to a second slack distance of the conveyor element.   
     
     
         4 . The conveyor system of  claim 3 , further comprising a third sensor positioned adjacent the sprocket and configured to generate a third output signal indicating the position of the flightbar, the third sensor positioned corresponding to a third slack distance of the conveyor element. 
     
     
         5 . The conveyor system of  claim 1 , wherein, to control the tensioning system based on the tension state, the electronic processor is configured to
 decrease the tension in the conveyor element when the tension state is over-tensioned, and   increase the tension in the conveyor element when the tension state is under-tensioned.   
     
     
         6 . The conveyor system of  claim 1 , further comprising:
 a second sprocket;   a second conveyor element of the conveyor, the second conveyor element coupled to the second sprocket to move around the second sprocket;   a second sensor positioned adjacent the sprocket and configured to generate a second output signal indicating the position of the flightbar; and   a second tensioning system,   wherein the electronic processor is coupled to the second sensor and to the second tensioning system, and wherein the electronic processor is further configured to
 receive the second output signal, and 
 determine the tension state of the conveyor based also on the second output signal, 
 wherein the flightbar is also supported by the second conveyor element and moves with the second conveyor element, and 
 wherein the second sensor is positioned corresponding to a second slack distance of the second conveyor element. 
   
     
     
         7 . The conveyor system of  claim 6 , wherein the sensor is positioned on a first side of the conveyor and the second sensor is positioned on a second side of the conveyor opposite the first side. 
     
     
         8 . A method for controlling tension in a conveyor element of a conveyor that moves around a sprocket, the method comprising:
 generating an output signal by a sensor positioned adjacent the sprocket, the output signal from the sensor indicative of a position of a flightbar of the conveyor supported by the conveyor element;   receiving, at an electronic processor, the output signal from the sensor;   determining, by the electronic processor, a tension state of the conveyor based on the output signal; and   controlling, by the electronic processor, a tensioning system based on the tension state to change a tension of the conveyor element.   
     
     
         9 . The method of  claim 8 , wherein the sensor is a binary proximity sensor, and wherein the sensor is positioned corresponding to a slack distance of the conveyor element. 
     
     
         10 . The method of  claim 8 , further comprising:
 generating a second output signal by a second sensor, the second output signal from the second sensor indicative of a second position of the flightbar,   receiving, at the electronic processor, the second output signal from the second sensor, wherein the second sensor is positioned corresponding to a second slack distance of the conveyor element, and   determining, by the electronic processor, the tension state of the conveyor also based on the second output signal.   
     
     
         11 . The method of  claim 10 , further comprising:
 generating a third output signal by a third sensor, the third output signal from the third sensor indicative of a third position of the flightbar,   receiving, at the electronic processor, the third output signal from the third sensor, wherein the third sensor is positioned corresponding to a third slack distance of the conveyor element, and   determining, by the electronic processor, the tension state of the conveyor also based on the third output signal.   
     
     
         12 . The method of  claim 8 , further comprising:
 decreasing the tension in the conveyor element when the tension state is over-tensioned, and   increasing the tension in the conveyor element when the tension state is under-tensioned.   
     
     
         13 . The method of  claim 8 , wherein the conveyor further includes a second conveyor element that moves around a second sprocket, the flightbar connecting the conveyor element and the second conveyor element, the method further comprising:
 generate a second output signal by a second sensor, the second output signal from the second sensor indicative of a second position of the flightbar supported by the second conveyor element;   receive, at the electronic processor, the second output signal from the second sensor, wherein the second sensor is positioned corresponding to a second slack distance of the second conveyor element; and   determine, by the electronic processor, the tension state of the conveyor based also on the second output signal.   
     
     
         14 . The method of  claim 13 , wherein the sensor is positioned on a first side of the conveyor and the second sensor is positioned on a second side of the conveyor. 
     
     
         15 . A controller for controlling tension in a conveyor element of a conveyor that moves around a sprocket, the controller including a non-transitory computer readable medium and an electronic processor, the controller comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:
 receive, at the electronic processor, an output signal from a sensor positioned adjacent the sprocket, the output signal from the sensor indicative of a position of a flightbar of the conveyor supported by the conveyor element;   determine, by the electronic processor, a tension state of the conveyor based on the output signal; and   control, by the electronic processor, a tensioning system based on the tension state to change a tension of the conveyor element.   
     
     
         16 . The controller of  claim 15 , wherein the sensor is a binary proximity sensor, and wherein the sensor is positioned corresponding to a slack distance of the conveyor element. 
     
     
         17 . The controller of  claim 15 , further comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:
 receive, at the electronic processor, a second output signal from a second sensor, wherein the second sensor is positioned corresponding to a second slack distance of the conveyor element, and   determine, by the electronic processor, the tension state of the conveyor also based on the second output signal.   
     
     
         18 . The controller of  claim 17 , further comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:
 receive, at the electronic processor, a third output signal from a third sensor, wherein the third sensor is positioned corresponding to a third slack distance of the conveyor element, and   determine, by the electronic processor, the tension state of the conveyor also based on the third output signal.   
     
     
         19 . The controller of  claim 15 , further comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:
 decrease the tension in the conveyor element when the tension state is over-tensioned, and   increase the tension in the conveyor element when the tension state is under-tensioned.   
     
     
         20 . The controller of  claim 15 , wherein the conveyor further includes a second conveyor element that moves around a second sprocket, the flightbar connecting the conveyor element and the second conveyor element, the controller further comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:
 receive, at the electronic processor, a second output signal from a second sensor positioned adjacent the second sprocket, the second output signal from the second sensor indicative of a second position of the flightbar supported by the second conveyor element; and   determine, by the electronic processor, the tension state of the conveyor also based on the second output signal.   
     
     
         21 - 39 . (canceled)