2
Field of the invention:-
The invention relates to material conveyors, field of magnetic gear and magnetic gear train configuration and generating electrical power.
Background of the invention:-
In industries like mining, steel making, etc., raw material transportation from one point to another is done by raw material handling conveyer system. The conveyer belt spans over few meters to many kilometers depending upon geography and requirement of the process. These conveyers are operated up to twenty four hours per day. Due to continuous running these systems also requires regular inspection of troughing rollers, pulleys, drive unit, belt tensioning arrangements, etc. to ensure uninterrupted operation. The conveyor capacity, belt speed, belt width etc. arc decided based on the type of requirement.
During transportation of material, roller provides support to conveyor belt and rotates about its own axis. The rotation of rollers happens due to the weight of raw material placed on the conveyor belt and belt tension, which creates friction between roller surface and conveyor belt. An extended shaft at both ends of bottom roller is used for mounting the magnetic gear which rotates at same RPM as the roller. The diameter of magnetic gear is decided based on the speed of the conveyor belt. This magnetic gear in turn rotates another magnetic gear mounted on the shaft of a generator. During this process electrical energy is produced by the generator. No additional power is required to rotate the gear system as the transmission is being done using magnetic force of permanent magnets mounted at the circumference of each gear. With the magnetic forces necessary torque is produced to rotate the shaft of electrical generator.

3 The drive force is applied at drive pulley with the help of gear box and motor which moves the conveyor belt towards discharge end. During transportation of raw material through conveyor belt, the weight of the material applies a force on rollers. The drive unit pulls the conveyer belt towards the discharge end and due to which friction is generated between belt and rollers. The purpose of these rollers is to provide mechanical support to conveyor belt otherwise it may sag under the weight of raw material, can cause spillage of raw material and damage to equipment. To reduce the friction between rollers and conveyor belt, bearings are used at both ends of roller. The friction between roller and conveyor is considered for power calculation of conveyor belt drive unit. Considerable amount of energy gets dissipated in overcoming friction due to roller.
It was observed that the energy dissipated in overcoming friction at rollers can be converted into electrical energy with the help of magnetic gear and modified sets of rollers.
Therefore, a set of magnetic gears is used to transmit rotational motion from roller shaft to generator input shaft. Here, step-up gear train is used to achieve a minimum 1500rpm for producing alternative current at the current at the operation of generator. Again, the speed of these conveyors depends upon the rate at which the raw material is needed at the consumer end.
Moritake, US. Pat. No. 3,713,521 discloses a braking system for a roller in a beltless conveyor, The braking system comprises an electrical generator and brake inside a conveyor roller. Electricity generated by the generator activates an electromagnetic brake inside the roller. All of the electrical power generated by Moritake’s generator is used to operate the electromagnetic brake or is dissipated in a variable resistor which may be used to vary the braking force.
Giconi. US. Pat. No. 3,987,307. discloses a system for generating electrical energy by dropping particulate material down a shall and directing the falling particulate matter into buckets around the periphery of a large

4 Wheel, similar to a “Water Wheel”. The Wheel turns as a result of the transference of kinetic energy from the falling particulate matter to the Wheel and the unbalanced Weight of particulate matter on the Wheel. The hub of the Wheel is coupled to an electrical generator.
Allan Patrick Stein. US Pat. 5970712 explains electrical energy generation in conveyor system which extends down a slope the conveyor system is driven by weight of material piled on the top surface of the conveyor belt. The invention explain to use the potential energy of a raw material in downhill conveyor in which the potential energy is converted to kinetic energy and then electrical energy. The kinetic energy of conveyor belt rotates and electrical generator mounted on the outer shaft support roller produces the electricity. But the required RPM and magnitude of produced electricity in not maintained.
This invention proposes 230V at the outlet of each generator and use it in series to light up conveyor galleries and run electrical appliance. The speed of belt varies from 1m/s to 3.5 m/s and accordingly the roller rpm also varies. The diameter of drive gear is increased or reduced as per requirement of input rpm of generator.
This arrangement can be installed in any conveyor. The magnetic gear uses magnetic force to drive the shaft of electrical generator. The torque required to rotate the main gear is transmitted by the friction force generated due raw material weight and belt tension between conveyor belt and the rollers. This invention can cater all type of illumination requirements around the conveyor facilities.
Object of the invention:-
An object of invention is to generate electricity without affecting the overall power consumption of conveyor drive unit.
Another object of invention is to produce electricity irrespective speed of conveyer belt.

5
Brief Description of accompanying drawing:-
The invention may be described with the reference to following detailed description and drawings.
Fig. 1 depicts side view of raw material handling conveyor belt system along with magnetic gear and generator system in accordance to the invention.
Fig. 2 shows Top view of conveyor belt system with electrical energy generation system installed at both sides of conveyor in accordance to the invention.
Fig. 3 shows Cross section view of conveyor belt system equipped with roller with extended shaft at both ends and magnetic gear arrangement along with power generating unit in accordance to the invention.
Fig.4 shows magnetic gear train in accordance to the invention.
Detailed description of accompanying drawings:-
Fig. 1 explains the typical arrangement of a conveyor system. A conveyor system consists of conveyor belt 4. head pulley 5. tail pulley 5, troughing rollers 6, return rollers , take-up pulley, counter weight/ belt tensioning device, gear box motor, raw material receiving point and discharge point.
The belt tensioning arrangement provides sufficient tension to conveyor belt to overcome sag in between two rollers due to material weight. The rollers are used to support the conveyor . These are equally spaced along the conveyor length of conveyor. The conveyor belts are driven by force generated by drive unit that consists of gear box, motor, couplings and drive pulley 5.
Due to friction, the roller rotates about its own axis. Typically, the shaft is fitted with bearings at both ends and roller rotates. In the modified arrangement the shaft is welded with shell of roller and both rotates as a

6
single unit. The extended shaft at both ends rotates with rollers, thereby producing a torque. The torque produced in this process is used to rotate a magnetic gear mounted on the shaft. This magnetic gear having a plurality of poles uniformly spaced along the circumference. The poles alternate from north to south polarity about the entire circumference of magnetic gear mounted on the input shaft of the electric generator.
The rotary motion from drive gear to driven gear is transmitted using magnetic force of attraction and repulsion. Hence in the entire process, the frictional energy is generated at the rollers is used to rotate the main drive magnetic gear and thus electricity is produced.
Fig-1. explains the overall arrangement of a conveyor system having a receiving hopper (1) and one discharge point. Raw material is collected in the hopper (1) and discharged to conveyor belt by feeding gates (2) installed at the bottom of the hopper. Conveyor belt (4) transports raw material (3) and delivers it at discharge point with the help of pulley (5) and idlers (6 and 7). The belt conveyor system consists of two pulleys (5), with an endless loop of carrying medium - the conveyor belt (4) - that rotates about them. One or both of the pulleys (5) are powered, moving the belt (4) and the material (3) on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley.
The produced electricity at each generation point is collected at collection point (15) through wire network (14). Part of generated electricity is used to charge batteries (16) and remaining is sent to power distribution network (17 and 18). Further, the electricity is distributed to individual consumer. The collection point (15) is a combination circuit in which output of more than one generator comes in and out of the unit (15) coupled directly to electrical appliances through transmission or it is sent for battery charging.
Fig.2 illustrates a modified idler and its support arrangement with power generating unit. Idlers (6) and (7) provide support to conveyor belt during raw material transportation. These idlers are one meter apart and equally spaced all along the conveyor. The idlers (6) are fitted in a frame whereas

7 idler(7) has its own separate fixing arrangement. Each idler (7) is supported at two points (13) and rotates about its own axis when conveyor moves in forward direction. Two magnetic gears (8) are installed at both ends of extended shafts (12) of idler (7). These magnetic gears (8) in-turn rotates smaller magnetic gears (9) mounted on the shaft of alternator (10).
Fig. 3 illustrates the cross sectional view of conveyor system with modified bottom roller and power generating unit. The extended shaft of bottom roller is supported at both the ends and it rotates about its own axis with the help of bearing (19) and transmits the rotation to magnetic gears attached to the power generating unit.
Fig.4 shows the magnetic gear arrangement. Gear (8) is mounted at the extended shaft of idler and rotates at the same rpm as of idlers depending upon belt speed. At the circumference of gear(8) and (9) natural magnets(20) are installed in a such a way that like pole i.e. north-north and south -south repel each other and this phenomena creates a circular motion in driven gear(9) when drive gear(8) rotate. The diameter of driven gear can increase or decrease as per the conveyor belt speed. The aim of this arrangement is to rotate the shaft of generator at 1500rmp and produce electrical energy.
This arrangement can be installed at any location in a conveyor. The produced electricity can be used for illumination of conveyor, charging of batteries and running of small electrical appliances.
This invention can reduce the overall energy requirement of a production plant. Most of the electricity is produced by burning of fossil fuel and reduction in consumption will also help in minimizing the overall carbon emission. All industry across the globe, involved in material transportation of any type by conveyor belt can use this product. The two desired input to this equipment are: (a) Rotation of drive gear through conveyor belt rollers

8 and (b) Magnetic force to rotate the driven gear. Both requirements will not influence overall energy demand of conveyor drive unit.

9
We claim:-
1. A conveyer system comprising a conveyer belt (4) head pulley (5), tail pulley (5), troughing, rollers (6), take up pulley, belt tensioning device, gear box motor, raw material receiving point and discharge point; wherein a conveyer shaft in welded with shell of roller;
wherein raw material is collected in a hopper (1) and transported to a discharge point means of drive pulley (5) and plurality of idler pulley characterized in that the said idler pulley (6) are fitted in a frame and idler pulley (7) is supported at two ends and coupled to a pair of magnetic gear (8) coupled to a pair of smaller magnetic gear (9); wherein electricity generated is collected at a collection point (15) by means of wire network(14).
2. The system as claimed in claim 1, wherein the idlers are distanced at one
meter approx.
3. The system as claimed in claim 1, wherein the magnetic gears are
installed at both ends of a extended shaft (12) of idler (7).
4. The system as claimed in claim 1, wherein the pair of magnetic gears (8) and smaller pair of magnetic gear (9) are so arranged such that the repulsive and attractive forces create circular motion.
5. The system as claimed in claim 1, wherein the electricity generated is supplied to batteries (16) and power distribution network (17 and 18).

6. The system as claimed in claim 1, substantially as herein described and illustrated in the drawings.