Description:CONVEYOR CARRYBACK COLLECTOR SYSTEM

FIELD OF INVENTION
The invention relates to the collecting and transferring of the carryback material falling off from the return side of a conveyor belt in a bulk material handling industry.
A conveyor carryback collector chain assembly constitutes a base tray for collecting the materials falling off from return side of the conveyor belt, after the conveyor belt discharges the material into the discharge chute. The system of chains and scraper blade assemblies create a combination of circular motion and linear motion in a direction opposite to the return belt travel to transfer the materials collected on the base tray back into the discharge chute. Thus the process eliminates the need of manual intervention for cleaning the spilled-off material from the return side of the belt.
BACKGROUND ART
In a bulk material handling industry, conveyor belts are the most effective way to transfer material from one place to another. Since its inception in the beginning of 20th Century, conveyor belts have been an integral part of the bulk material handling industry. It is used in industries like mines, mineral processing, plants, coal powered power plants, cement plants, ports, and in any other plants which require transferring bulk solids. Although various changes and innovation have taken place in material conveyance through conveyor belts in the past 100 years, one problem that is still associated with the bulk material handling is the problem of material spillage. Spillage can occur at different location of the conveyor. It can take place during loading, while conveying along the length of the conveyor and during discharge. All these spillage increases cost for the plant owners. The particular invention relates to the spillage that occurs at the discharge end of the conveyor belt.
The continuously running conveyor belt carrying material with it generates huge amount of carryback, which if not cleaned can settle beneath the conveyor belt across its length. A majority of this carryback is collected beneath and just after the snub pulley. This collection of carryback generates an unsafe working environment along with material loss, production disruption, unscheduled conveyor shutdown and engagement of manpower for cleaning. All these affects the plant owners in terms of monetary losses.
In prior inventions scrapers or belt cleaners have been ideated, designed and put on the return side of the belts for cleaning and maintaining the efficiency. But certain conveyors are constructed so critically that the construction does not allow the mounting of proper belt cleaners on the return side of the belt. Also, in some cases the belt efficiency of the belt cleaner is limited due to certain constraints. In both these cases heavy spillage forms on the return side of the belt creating an unsafe working environment. Such a situation leads to the rise of other factors which is already discussed earlier in detail.
SUMMARY OF INVENTION
Thus it is an object of the invention to reduce the amount of carryback collection beneath the return side of the conveyor belt by collecting the carryback spillage which may lead to an unsafe working environment and transfer it to the Chute through the cut-out in the chute back plate with the main stream of materials.
The herein disclosed conveyor carryback collector chain assembly having a base tray for collecting the materials falling off from return side of the conveyor belt, after the conveyor belt discharges the material into the discharge chute. The system of chains and scraper blade assemblies create a combination of circular motion and linear motion in a direction opposite to the return belt travel to transfer the materials collected on the base tray back into the discharge chute. Thus the process eliminates the need of manual intervention for cleaning the spilled-off material from the return side of the belt.
Thus according to the present invention, it is provided that the present system comprises of a Base Collector Tray for collecting the accumulated carryback material whose design is modular with unique fixings. There are two side walls, one parallel & one of 45 degree each, & a Back Plate, which guides & contains the carryback material within the Base Collector Tray. The modular Scraper blades in the Scraper Assembly System are being driven at certain pre-decided intervals by the electro-mechanical transmission system. The pre-decided intervals are being set-up by the logic controller and load-weigh scale. A take-up bearing is mounted at the front-end of both the parallel walls for maintaining chain tension. The electro-mechanical system has a covering with dust curtain and a serviceable flange for periodic manual maintenance.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 is a perspective view of the Carryback collector system in accordance with the present invention;
Figure 2 is an isometric view of the Scraper assembly in accordance with the present invention;
Figure 3(a) to (d) shows the different arrangements by which the Base Collector plate can be connected to each other in accordance with the present invention;
Figure 4 shows a varied version of the Carryback collector system with a dust covering for the electromechanical systems & a serviceable flange in accordance with the present invention.
DETAILED DESCRIPTION
A conveyor carryback collector chain assembly having a base tray for collecting the materials falling off from return side of the conveyor belt, after the conveyor belt discharges the material into the discharge chute. The system of chains and scraper blade assemblies create a combination of circular motion and linear motion in a direction opposite to the return belt travel to transfer the materials collected on the base tray back into the discharge chute. Thus the process eliminates the need of manual intervention for cleaning the spilled-off material from the return side of the belt.
Referring now to the drawings, Fig 1-3 show Base collector (large) 1 connected with the Base Collector (small) 2 by various fixing arrangements as shown in Fig 3 through Figures 3A to 3D. Fig 3A is a first-type fixing where the two Base collectors Base collector (large) 1 & Base Collector (small) 2 are connected by means of mechanical fasteners. Fig 3B is a second-type fixing where the two Base collectors Base collector (large) 1 & Base Collector (small) 2 are connected in a tray-in-tray arrangement where the Base collector (small) 2 is placed within the Base collector (large) and follows a designed path as shown in fig 3B during unfolding. Fig 3C is a third-type fixing where the two Base collectors Base collector (large) 1 & Base Collector (small) 2 are connected by means of pin and latches. Fig 3D is a fourth-type fixing where the two Base collectors Base collector (large) 1 & Base Collector (small) 2 are connected by means of locking curved flange. The Base Collector (large) 1 & Base Collector (small) 2 collects the carryback material falling from the return side of the conveyor belt and the snub pulley. The combination of 1 & 2 prevents the material from falling onto the ground. The Inclined Side flange 3, the Side flange 4 & the Back plate 10 provide rigidity to the Carryback Collector system and defines the boundary region of the Carryback Collector system within which the falling carryback material remains confined. The inclined profile of the Inclined Side flange 3 guides the falling carryback material within a designated cleaning width of the Scraper assembly 13. The Electro-mechanical system consists of a Gear motor 6, Link chain assembly 5, Take-up bearing 7, Sprocket 8, Flange bearing 9,Idler shaft 11 & Drive Shaft 12. The combination of the above mentioned Electro-mechanical system provides a combined rotary & linear motion to the Scraper Assembly 13. The Scraper assembly 13 as shown in figure 2 is connected to the Link Chain-chain assembly 5 by a chain mounting plate 13B. 13B is connected to the Scraper pipe 13A which in turn holds the Blade mounting plate 13C. The Scraper blades 13D is fixed with the Blade mounting plate 13C.
In an embodiment, the said conveyor carryback collector is placed under the snub pulley and the return side of the belt of a belt conveyor and inserted through the cut-out of the chute back plate such that it collects the carryback material falling off from the snub pulley and the return belt & transfers the material back to the designated chute avoiding accumulation of carryback spillage below the belt & eliminating the requirement of manual cleaning & loss of material.
The Carryback Collector system comprises of a) a Base Collector Tray whose primary function is to collect the carryback material falling off from the snub pulley & the return side of the belt, b) two side walls, one parallel & one of 45 degree on each side of the Base Collector Tray to guide the material within the designated cleaning zone, c) a Back plate to provide structural rigidity to the system d) scraper assembly system for cleaning the carryback material collected e) electromechanical transmission system which provides a required motion to the scraper assembly for transferring the collected carryback material into the chute with the main stream of material flow, f) a take-up bearing unit to adjust the tension of the chain g) a covering with dust curtain to protect the direct falling of the carryback material onto the chain and to avoid clogging of the chain h) a serviceable flange covering the electro-mechanical transmission systems which can be taken out during the servicing of the said transmission system i) a logic controller for periodic operation of the electro-mechanical transmission system j) a load-weigh scale integrated with the logic controller for periodic operation of the electro-mechanical system.
In another embodiment, the said base collector tray is a modular tray with different mechanical fixings and tray-in tray design which can be adjusted & fitted according to the belt width. The two side walls, one parallel & one of 45 degree on each side of the said Base collector tray is also connected to the Base Collector Tray mechanically & guides the material falling inside the system to be within the designated cleaning width and also holds the different electro-mechanical transmission systems. Further the said system includes a back plate of the collector tray operably connected with both the Base Collector Tray & the two side walls, one parallel & one of 45 degree on each side provides a rigidity to the system and also acts as the boundary for the system within which the carryback gets collected so that there is no scattering and loss of the falling material.
In another embodiment, the said scraper assembly includes a metallic pipe which holds the scraper blades to be used for cleaning the collected carryback material from the Base Collector Tray and transfer the carryback material into the chute through the cut out in the chute back plate. The said scraper assembly includes scraper blades which are modular in design and are replaceable by individual modules in case of wearing out; scraper blades are provided with a vertical slot for individual adjusting of the blade in case of wearing out.
In another embodiment, the scraper blade is inclined at a certain degree against the direction of scraper movement so that it can efficiently transfer the material collected on the Base Collector Tray & is connected to the electromechanical transmission system which generates the motion. The said scraper assembly is attached to the electromechanical transmission system which, revolves in a pre-designed path with a forward movement towards the chute back plate opening while transferring the collected material into the chute and with a backward movement while retracting, which is followed up by the forward movement.
In another embodiment, there is also provided a take-up bearing system mounted on the parallel side wall on both sides of the system and provides the necessary tension to the electromechanical transmission system, which can be manually adjusted during servicing. The said electromechanical transmission system includes a covering with the dust curtain configured to provide a protection to the electromechanical transmission system against the falling dust and moisture which may cause erosion to the link chain assembly disrupting its motion. The said covering with the dust curtain includes serrated rubber curtains of varied thickness through which the metallic pipe of the scraper blade system moves and revolves through a designated path.
In another embodiment there is provided two serviceable flanges operably attached mechanically or with a tray-in-tray arrangement to the two side walls running across the entire length of the tray and covering the electromechanical systems so that the electromechanical system can be protected against dust and moisture. The said two serviceable flanges are designed in such a way so that they can be taken out at any point of time during periodic servicing of the electromechanical parts.
In yet another embodiment there is provided a logic controller as claimed in claim 2 periodically activates and disrupts the electromechanical system for a designated period of time and by virtue of which the scraper blade assembly system completes a designated number of revolutions which is designed considering the material nature and the amount of carryback material settling on the Base Collector Tray. The collector tray optionally includes a Load-Weigh Scale configured to determine the weight of the system with the carryback material on the Base Collector Tray and triggers an alarm to the logic controller to initiate the controller’s process.
The varied version of the Carryback collector system as illustrated in Fig 4 consists of the components from 1 to 13 as illustrated in the Fig 1. The variation in the design comes with the addition of the components 14 & 15. The combination of the dust curtain 14A & the chain covering 14B prevents the carryback material from directly falling on the link-chain assembly. The serviceable flange 15 is attached the Inclined side flange 3 and the Side flange 4 and provides serviceability to the customer.
Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration by way of examples and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
, Claims:We claim:
1. A conveyor carryback collector system comprises of:
a Base Collector Tray whose primary function is to collect the carryback material falling off from the snub pulley & the return side of the belt,
two side walls, one parallel & one of 45 degree on each side of the Base Collector Tray to guide the material within the designated cleaning zone,
a Back plate to provide structural rigidity to the system
a scraper assembly system for cleaning the carryback material collected
an electromechanical transmission system which provides a required motion to the scraper assembly for transferring the collected carryback material into the chute with the main stream of material flow,
a take-up bearing unit to adjust the tension of the chain
a covering with dust curtain to protect the direct falling of the carryback material onto the chain and to avoid clogging of the chain
a serviceable flange covering the electro-mechanical transmission systems which can be taken out during the servicing of the said transmission system; and
a logic controller for periodic operation of the electro-mechanical transmission system j) a load-weigh scale integrated with the logic controller for periodic operation of the electro-mechanical system.
2. The conveyor carryback collector system as claimed in claim 1, wherein said Base Collector Tray is placed under the snub pulley and the return side of the belt of a belt conveyor and inserted through the cut-out of the chute back plate such that it collects the carryback material falling off from the snub pulley and the return belt & transfers the material back to the designated chute avoiding accumulation of carryback spillage below the belt & eliminating the requirement of manual cleaning & loss of material.
3. The conveyor carryback collector system as claimed in claim 1, wherein said Base Collector Tray is a modular tray with different mechanical fixings and tray-in tray design which can be adjusted & fitted according to the belt width.
4. The conveyor carryback collector system as claimed in claim 1, wherein the two side walls, one parallel & one of 45 degree on each side of the Base collector tray is also connected to the Base Collector Tray mechanically & guides the material falling inside the system to be within the designated cleaning width and also holds the different electro-mechanical transmission systems.
5. The conveyor carryback collector system as claimed in claim 1, wherein said Back plate of the collector Tray is connected with both the Base Collector Tray & the two side walls, one parallel & one of 45 degree on each side provides a rigidity to the system and also acts as the boundary for the system within which the carryback gets collected so that there is no scattering and loss of the falling material.
6. The conveyor carryback collector system as claimed in claim 1, wherein said scraper assembly system contains a metallic pipe which holds the scraper blades to be used for cleaning the collected carryback material from the Base Collector Tray and transfer the carryback material into the chute through the cut out in the chute back plate.
7. The conveyor carryback collector system as claimed in claim 1, wherein said the scraper blades of the scraper assembly system are modular in design and replaceable by individual modules in case of wearing out; scraper blades are provided with a vertical slot for individual adjusting of the blade in case of wearing out.
8. The conveyor carryback collector system as claimed in claim 1, wherein said the scraper blade assembly is inclined at a degree against the direction of scraper movement so that it can efficiently transfer the material collected on the Base Collector Tray & is connected to the electromechanical transmission system which generates the motion.
9. The conveyor carryback collector system as claimed in claim 1, wherein said scraper assembly attached to the electromechanical transmission system, revolves in a pre-designed path with a forward movement towards the chute back plate opening while transferring the collected material into the chute and with a backward movement while retracting, which is followed up by the forward movement.
10. The conveyor carryback collector system as claimed in claim 1, wherein said take-up bearing system is mounted on the parallel side wall on both sides of the system and provides the necessary tension to the electromechanical transmission system, which can be manually adjusted during servicing.
11. The conveyor carryback collector system as claimed in claim 1, wherein said covering with the dust curtain provides a protection to the electromechanical transmission system against the falling dust and moisture which may cause erosion to the link chain assembly disrupting its motion.
12. The conveyor carryback collector system as claimed in claim 1, wherein said covering with the dust curtain contains serrated rubber curtains of varied thickness through which the metallic pipe of the scraper blade system moves and revolves through a designated path.
13. The conveyor carryback collector system as claimed in claim 1, wherein said two serviceable flanges are attached mechanically or with a tray-in-tray arrangement to the two side walls running across the entire length of the tray and covering the electromechanical systems so that the electromechanical system can be protected against dust and moisture.
14. The conveyor carryback collector system as claimed in claim 1, wherein said two serviceable flanges are designed in such a way so that they can be taken out at any point of time during periodic servicing of the electromechanical parts.
15. The conveyor carryback collector system as claimed in claim 1, wherein said logic controller periodically activates and disrupts the electromechanical system for a designated period of time and by virtue of which the scraper blade assembly system completes a designated number of revolutions which is designed considering the material nature and the amount of carryback material settling on the Base Collector Tray.
16. The conveyor carryback collector system as claimed in claim 1, wherein said Load-Weigh Scale determines the weight of the system with the carryback material on the Base Collector Tray and triggers an alarm to the logic controller to initiate the controller’s process.