CLIAMS:We Claim:

1. Online roller replacement equipment for selective idler repair/replacement from moving trough conveyors comprising

a roller rotatably mounted on a shaft providing for load support to conveyor with low resistance to movement;

one upwardly disposed end of said shaft angularly operatively connected to a height adjusting means such that the vertical distance of said upwardly disposed end of the said connected end of the shaft can be suitably adjusted for desired inclination support for the moving trough conveyor;

other downwardly disposed end of said shaft operatively connected to a guide and lock arrangement for adjusting and fixing the selective widthwise positioning of the roller under the trough conveyor for desired on-line positional support for selective idler repair/replacement.

2. Online roller replacement equipment as claimed in claim 1 comprising a base frame supporting at one end said height adjusting means and at the other end said guide and lock arrangement which together provide for selective inclined supportive disposition of the shaft with roller for lifting and lowering of said shaft with roller agaisn the moving conveyer for desired idler repair/replacement.

3. Online roller replacement equipment as claimed in anyone of claims 1 or 2 comprising
a base frame to provide stable support to the equipment when removably installed on conveyor platform for roller replacement purpose;
a roller rotatably mounted on a shaft to provide load support to conveyor with low resistance to movement;
a turn buckle with adjustable screw pivoted at one end on a first bracket fixed at front end of the base frame, for lifting and lowering of said roller with shaft;
a guide block mounted on said roller shaft pivoted on a second bracket fixed at rear end of the base frame to enable length adjustment of roller shaft and provide trunion action;
a locking arrangement with wing nut for locking the adjusted length of the roller shaft;
other end of said turn buckle with adjustable screw is pivotally connected to the opposite end of said roller shaft such that when the turn buckle is rotated with respect to the adjustable screw, overall length of the turn buckle is extended or shortened and accordingly the angle of inclination of the roller with shaft is increased or decreased depending on clockwise or anticlockwise direction of rotation of the turn buckle to gradually provide load support to the moving conveyor or make it free of load as per need and to create required gap to favour replacement of damaged idler with spare.

4. Online roller replacement equipment as claimed in anyone of claims 1 to 3 wherein position of roller with respect to width of conveyor is adjusted by adjusting the length of the roller shaft between the pivot points at front and rear end by unlocking the wing nut and moving the shaft forward or backward through guide block and finally locking the nut after correct position is reached with the equipment placed under the conveyor beside any damaged idler to be replaced.

5. Online roller replacement equipment as claimed in anyone of claims 1 to 4 which is adapted to replace damaged roller in any trough angle conveyor having width in the range of preferably 1 m, subjected to variable load.

6. Online roller replacement equipment as claimed in anyone of claims 1 to 5 wherein the diameter of roller shaft is selected so that buckling of shaft is avoided during online replacement of damaged idler.

7. Online roller replacement equipment as claimed in anyone of claims 1 to 6 wherein the length of the turn buckle and the roller shaft is adjustable between the respective pivot points to favour positioning of roller with respect to conveyor belt width and also loading/unloading of conveyor load on roller.

8. A method of replacement of damaged idler roller of trough angle conveyor involving the roller replacement equipment as claimed in claims 1 to 7 comprising
(i) reducing the angle of the online roller replacement arrangement by adjusting the turn buckle with adjustable screw;
(ii) placing the online roller replacement equipment on its base frame on conveyor platform under the running conveyor belt keeping gap between roller and conveyor belt;
(iii) adjusting the position of the roller of the equipment in relation to conveyor width by using the guide block and locking the correct position using wing nut of the locking arrangement.
(iv) adjusting the length of turn buckle with adjustable screw by rotating the turn buckle so that roller of online roller replacement equipment takes the load of the running belt and adjustment is continued untill the load was taken completely by the equipment and a gap is created between the damaged idler and conveyor which becomes free of load of running conveyor belt to enable damaged idler replacement.
(v) replacing the damaged idler with a spare new one.
(vi) gradually releasing the load of running conveyor belt from the equipment and transferring the same to replaced idler roller and creating a gap between the equipment and the conveyor belt by adjusting turn buckle until the replaced idler roller starts working.
(vii) finally releasing the online roller replacement equipment from conveyor and removing from the work site.

9. A method as claimed in claim 8, wherein the angle of the online roller replacement arrangement can be increased or decreased by adjusting the turn buckle with adjustable screw to lift or lower the running belt to release load on damaged idler or take load on replaced spare idler.

10. A method as claimed in anyone of claims 7 or 8, wherein the roller replacement equipment is temporarily used during replacement of damaged idlers in online mode.

11. A method as claimed in anyone of claims 7 to 10, wherein one person is enough to replace any damaged idler comfortably with very less effort and time.
Dated this the 31st day of March, 2015
Anjan Sen
Of Anjan Sen & Associates
(Applicants Agent)
,TagSPECI:FIELD OF THE INVENTION

The present invention relates to an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor. More particularly, the present invention is directed to provide an apparatus comprising a combination of components like link, turn buckle, roller, base, trunion, guide block and lock arrangement configured in such a way that is compact and easy to handle and also favour easy replacement of damaged idler roller of any trough angle conveyor while in operation. The equipment is designed for easy handling of any trough angle conveyor’s carrying damaged idlers changing operation with less manpower without stopping the conveyor, thus reducing down time and increasing plant availability.

BACKGROUND OF THE INVENTION

Belts are troughed to allow the conveyor to carry more material. As the trough angle is increased, more material can be carried. All flat rubber or PVC belts can be formed into a trough by idlers. The type of belt carcass, the thickness of the belt, the width of the belt, and the tension rating of the belt determine the maximum trough angle. On belting manufacturers’ technical data sheets, troughability is typically shown as the minimum belt width allowed for the various trough angles. If the belt’s troughability is not compatible with the troughing idlers, it might take more power to operate the conveyor than originally designed.

Usually the idlers used in trough angle conveyors are made of ERW MS Pipe of 4.85 mm thickness with shield bearings. Role of an idler is to provide load support with low resistance to movement for the trough angle conveyors. Even though, a predictive maintenance schedule suggests replacing idlers once in 2 years, idlers fail more frequently. Because of the shield bearing and due overload some of the bearings may damage prematurely during running. Hence replacement of idlers is a regular requirement for trough angle conveyors.

In conventional practice, if a damaged idler is to be replaced, at least three maintenance persons are required and conveyor has to be stopped. Two persons have to lift the belt with crow bar and one replaces the damaged idler with spare one. More effort is required due to belt tension. Also time required to replace the damaged roller with a spare new roller takes much time. Consequent delay and loss of production is unavoidable.

There has been therefore a continuing need in the field of material handling using trough angle conveyor to develop an equipment and method to replace damaged idler rollers without stopping the conveyor and using minimum manpower at less time thus saving loss of production.

OBJECTS OF THE INVENTION

The basic object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor which would enable replacement of damaged idler without stopping the running conveyor.

A further object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor wherein the equipment enable use of minimum manpower and an individual worker can carry out the roller replacement work single handedly.

A still further object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor wherein appropriate mechanisms are provided to adjust to and fit any angular disposition of idler roller in trough conveyor.

A still further object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor wherein belt lifting for replacement of damaged idler is performed by mechanical means without needing much physical effort.

A still further object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor which enable entire task of idler roller replacement can be done in much less time without interrupting the ongoing conveyor operation.

A still further object of the present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor which favours easy maintenance and safe working condition.

SUMMARY OF THE INVENTION

The basic aspect of the present invention is directed to an online roller replacement equipment for selective idler repair/replacement from moving trough conveyers comprising

a roller rotatably mounted on a shaft providing for load support to conveyor with low resistance to movement;

one upwardly disposed end of said shaft angularly operatively connected to a height adjusting means such that the vertical distance of said upwardly disposed end of the said connected end of the shaft can be suitably adjusted for desired inclination support for the moving trough conveyor;

other downwardly disposed end of said shaft operatively connected to a guide and lock arrangement for adjusting and fixing the selective widthwise positioning of the roller under the trough conveyor for desired on-line positional support for selective idler repair/replacement.

A further aspect of the present invention is directed to an online roller replacement equipment comprising a base frame supporting at one end said height adjusting means and at the other end said guide and lock arrangement which together provide for selective inclined supportive disposition of the shaft with roller for lifting and lowering of said shaft with roller against the moving conveyer for desired idler repair/replacement.

A still further aspect of the present invention is directed to an online roller replacement equipment comprising
a base frame to provide stable support to the equipment when removably installed on conveyor platform for roller replacement purpose;
a roller rotatably mounted on a shaft to provide load support to conveyor with low resistance to movement;
a turn buckle with adjustable screw pivoted at one end on a first bracket fixed at front end of the base frame, for lifting and lowering of said roller with shaft;
a guide block mounted on said roller shaft pivoted on a second bracket fixed at rear end of the base frame to enable length adjustment of roller shaft and provide trunion action;
a locking arrangement with wing nut for locking the adjusted length of the roller shaft;
other end of said turn buckle with adjustable screw is pivotally connected to the opposite end of said roller shaft such that when the turn buckle is rotated with respect to the adjustable screw, overall length of the turn buckle is extended or shortened and accordingly the angle of inclination of the roller with shaft is increased or decreased depending on clockwise or anticlockwise direction of rotation of the turn buckle to gradually provide load support to the moving conveyor or make it free of load as per need and to create required gap to favour replacement of damaged idler with spare.

A still further aspect of the present invention is directed to an online roller replacement equipment wherein position of roller with respect to width of conveyor is adjusted by adjusting the length of the roller shaft between the pivot points at front and rear end by unlocking the wing nut and moving the shaft forward or backward through guide block and finally locking the nut after correct position is reached with the equipment placed under the conveyor beside any damaged idler to be replaced.

A still further aspect of the present invention is directed to an online roller replacement equipment which is adapted to replace damaged roller in any trough angle conveyor having width in the range of preferably 1m, subjected to variable load.
A still further aspect of the present invention is directed to an online roller replacement equipment wherein the diameter of roller shaft is selected so that buckling of shaft is avoided during online replacement of damaged idler.

A still further aspect of the present invention is directed to an online roller replacement equipment wherein the length of the turn buckle and the roller shaft is adjustable between the respective pivot points to favour positioning of roller with respect to conveyor belt width and also loading/unloading of conveyor load on roller.

Yet another aspect of the present invention is directed to a method of replacement of damaged idler roller of trough angle conveyor involving the roller replacement equipment as described above comprising
(i) reducing the angle of the online roller replacement arrangement by adjusting the turn buckle with adjustable screw;
(ii) placing the online roller replacement equipment on its base frame on conveyor platform under the running conveyor belt keeping gap between roller and conveyor belt;
(iii) adjusting the position of the roller of the equipment in relation to conveyor width by using the guide block and locking the correct position using wing nut of the locking arrangement.
(iv) adjusting the length of turn buckle with adjustable screw by rotating the turn buckle so that roller of online roller replacement equipment takes the load of the running belt and adjustment is continued untill the load was taken completely by the equipment and a gap is created between the damaged idler and conveyor which becomes free of load of running conveyor belt to enable damaged idler replacement.
(v) replacing the damaged idler with a spare new one.
(vi) gradually releasing the load of running conveyor belt from the equipment and transferring the same to replaced idler roller and creating a gap between the equipment and the conveyor belt by adjusting turn buckle until the replaced idler roller starts working.
(vii) finally releasing the online roller replacement equipment from conveyor and removing from the work site.

A further aspect of the present invention is directed to a method wherein the angle of the online roller replacement arrangement can be increased or decreased by adjusting the turn buckle with adjustable screw to lift or lower the running belt to release load on damaged idler or take load on replaced spare idler.

A still further aspect of the present invention is directed to a method wherein the roller replacement equipment is temporarily used during replacement of damaged idlers in online mode.

A still further aspect of the present invention is directed to a method wherein one person is enough to replace any damaged idler comfortably with very less effort and time.

The above and other objects and advantages of the present invention are described hereunder in greater details with reference to the following accompanying non limiting illustrative drawings.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

Figure 1: shows the top view of a stretch of conventional trough angle conveyor between the head pulley and tail pulley involving an arrangement of trough type carrying idlers roller assembly.
Figure 2: shows the front view of conventional arrangement of a row of idler roller assembly comprising one horizontal and two inclined rollers to support the load of trough type conveyor.
Figure 3: is the photograph illustrating the conventional method of replacing the damaged idler roller in trough angle conveyor.
Figure 4: is the front view of the complete assembly of the online roller replacement equipment according to the present invention showing the main components of the equipment.
Figure 5: is the photograph showing the position of use of the online roller replacement equipment according to the present invention for replacing any damaged idler roller in trough angle conveyor when the conveyor remains in operation.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES

The present invention is directed to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor which would enable replacement of damaged idler without stopping the running conveyor in a simple and safe manner using less manpower, less effort and less time.

It has already been stated that conveyor belts are troughed to allow the conveyor to carry more material. As the trough angle is increased, more material can be carried. All flat rubber or PVC belts can be formed into a trough by use of idlers. Accompanying Figure 1 shows the top view of a stretch of conventional trough angle conveyor between the head pulley and tail pulley involving an arrangement of trough type carrying idlers roller assembly. Accompanying Figure 2 shows the front view of conventional arrangement of a row of idler roller assembly comprising one horizontal and two inclined rollers to support the load of trough type conveyor. It is already stated that because of the shield type bearing and due to overload these are subjected to, some of the bearings may damage prematurely during running and idler rollers fail more frequently needing replacement.

Conventionally when a damaged idler is to be replaced, at least three maintenance persons are required and conveyor essentially has to be stopped. Two persons have to lift the belt with crow bar and one replaces the damaged idler with spare one. Much more effort is required due to belt tension and applied load. This method of replacing idlers are unsafe and requires more time causing substantial loss of plant availability. Accompanying Figure 3 is the photograph illustrating the conventional method of replacing the damaged idler roller in trough angle conveyor.

The present invention thus targets to solve the disadvantages and limitations of the conventional idler roller replacement in trough angle conveyor by developing an online roller replacement equipment. Accompanying Figure 4 is the front view of the complete assembly of the online roller replacement equipment according to the present invention showing the main components of the equipment. The equipment has a base frame(A) portion made of metallic plate. There are two brackets welded at front and rear end of the base frame(A) to provide pivot support. At the front bracket(F), one end of turn buckle with adjustable screw(E) is mounted and at the rear bracket(G), one end of a shaft(H) with idler roller(D) is connected. The roller (D) is mounted on shaft(H) with bearings to rotate with minimum frictional resistance. The other end of the turn buckle with adjustable screw(E)is pivotally connected with the opposite end of the roller shaft(H), such that when the turn buckle(E) is rotated with respect to the adjustable screw, overall length of the turn buckle is extended or shortened and accordingly the angle of inclination of the roller(D) is increased or decreased depending on clockwise or anticlockwise direction of rotation of the turn buckle. A guide block(B) and a locking arrangement(C) with wing nut is provided at the pivoted bracket end of the roller shaft such that the position of roller(D) can be adjusted in relation to conveyor width before loading when put in service for replacement of any damaged idler roller and locked. Thus the invented equipment has thus the following salient features:
Base frame(A)- For better support when installed on conveyor frame;
Guide block(B)-For length adjustment and trunion action;
Locking arrangement with Wing nut(C)-Locking the adjusted length;
Roller(D) with shaft(H)- Provide load support with low resistance to movement;
Turn buckle with adjustment screw(E)-For lifting and lowering the roller(D);

The different components of the equipment, including particularly the roller shaft(H), are selectively designed to sustain the static as well as dynamic load conditions to which the equipment is subjected to under the condition of online application. The dimensions of the different components of the equipment can be suitably selected to suit any width and load carrying capacity of the conveyor. A sample design calculation to determine the roller shaft diameter/rod dimension based on given conveyor size and load conditions are presented below:

CALCULATION:
Width of the belt= 1000 mm
Speed = 2.3 m/s
Assuming we may use a belt with a resistance class equal to 315 N/mm, with cover thickness 4+2, and with a value qb of 9.9 kg/m.
Principal relevant factors:
Iv = belt load t/h
v = belt speed m/s
ao = pitch of the troughing sets upper strand m
qb = weight of belt per linear metre Kg/m
Fd = impact factor (see Table below) (depends on the material lump size)
Fs = service factor (see Table below)
Fm = environment factor (see Table below)
P=Buckling load=Ca1
E=Young`s modulus 2.1x105 N/mm2 (For mild steel)
n=Coefficient of end connection
L=Length
r=least radius of gyration
sy=Yield stress 410 N/mm2(For mild steel)

CONVEYOR STATIC LOAD:

Ca = ao x (qb + lv/3.6xv )x 0,981 [daN]
Ca=1.2 x ( 9.9 +(1000/3.6x2.3))x0.981
Ca=153.8 daN

Conveyor static load Ca=1538 N

CONVEYOR DYNAMIC LOAD:
Ca1= Ca x Fd x Fs x Fm [daN]
Ca1=153.8 x1.03x1.2X1
Ca1= 190 daN

Conveyor Dynamic load Ca1= 1900 N

BUCKLING LOAD FOR ONLINE CARRYING ROLLER REPLACEMENT EQUIPMENT

P=asy[1-(sy/4np2E)(L/r)2] for L/r< 120

1900=a410[1-(410/4x2x3.142x2.1x105)(440/10)2]

a=4.72 mm2

pr2= 4.86

r= 1.24 mm

Required diameter = 2.5 mm

Equipment rod diameter = 20 mm

Equipment roller shaft diameter is 20mm > required diameter of 2.5 mm
Hence the design is safe

The online roller replacement equipment as illustrated in Figure 4 is temporarily installed on the conveyor platform during replacement of damaged idlers in online mode. The base(A) of the equipment is rested on the conveyor platform below the moving conveyor adjacent to any damaged idler. Accompanying Figure 5 is the photographic image showing the position of use of the online roller replacement equipment according to the present invention for replacing any damaged idler roller in trough angle conveyor when the conveyor remains in operation. Firstly, the angle of the online roller replacement arrangement is reduced by adjusting turn buckle with adjusting screw(E) such it does not make contact with running conveyor. Next , the length of the equipment is adjusted with the help of Guide block(B) and unlocking the locking arrangement(C) and after final positioning of the roller(D) in relation to conveyor width, the position is locked using locking arrangement (C). Now by using the turn buckle with adjustable screw(E), the angle of inclination of the idler roller attached to the online roller replacement equipment is increased to lift the running belt and to load on Roller(D). Hence, roller(D) of the equipment free the load from the damaged idler which needs to be replaced and create gap for replacement with a spare new roller. In the next step, the damaged idler is replaced with spare idler. Then, the load on roller(D) of the equipment is slowly reduced by reducing the angle by turning turn buckle(E) untill the changed idler started taking load. When sufficient gap is created between the online roller replacement arrangement and belt, remove the equipment from the area.

Thus the steps involved in the procedure for online replacement of damaged idler using the invented equipment are as follows:
(i) Preparatory work like spare idlers, online roller changing equipment and other required tools to be kept ready;
(ii) reducing the angle of the online roller replacement arrangement by adjusting the turn buckle with adjustable screw;
(iii) placing the online roller replacement equipment on its base frame on conveyor platform under the running conveyor belt keeping gap between roller and conveyor belt;
(iv) adjusting the position of the roller of the equipment in relation to conveyor width by using the guide block and locking the correct position using wing nut of the locking arrangement.
(v) adjusting the length of turn buckle with adjustable screw by rotating the turn buckle so that roller of online roller replacement equipment takes the load of the running belt and adjustment is continued untill the load was taken completely by the equipment and a gap is created between the damaged idler and conveyor which becomes free of load of running conveyor belt to enable damaged idler replacement.
(vi) replacing the damaged idler with a spare new one.
(vii) gradually releasing the load of running conveyor belt from the equipment and transferring the same to replaced idler roller and creating a gap between the equipment and the conveyor belt by adjusting turn buckle until the replaced idler roller starts working.
(viii) finally releasing the online roller replacement equipment from conveyor and removing it from the work site.

It is thus possible by way of the present invention to provide an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor to enable replacement of any damaged idler while the conveyor is in operation under load wherein the equipment enable transfer of load of moving conveyor from damaged roller to adjacent roller of the equipment temporarily by adjusting the linkages of the equipment so that the damaged idler which becomes free of load is replaced by a spare one and thereafter the load is again transferred back to the replaced spare roller and the equipment is released and removed while the conveyor operation continues. The roller replacement using the equipment according to the present invention is done in a simple, safe, faster and efficient manner with less manpower ensuring increased plant availability.

We Claim:

1. Online roller replacement equipment for selective idler repair/replacement from moving trough conveyors comprising

a roller rotatably mounted on a shaft providing for load support to conveyor with low resistance to movement;

one upwardly disposed end of said shaft angularly operatively connected to a height adjusting means such that the vertical distance of said upwardly disposed end of the said connected end of the shaft can be suitably adjusted for desired inclination support for the moving trough conveyor;

other downwardly disposed end of said shaft operatively connected to a guide and lock arrangement for adjusting and fixing the selective widthwise positioning of the roller under the trough conveyor for desired on-line positional support for selective idler repair/replacement.

2. Online roller replacement equipment as claimed in claim 1 comprising a base frame supporting at one end said height adjusting means and at the other end said guide and lock arrangement which together provide for selective inclined supportive disposition of the shaft with roller for lifting and lowering of said shaft with roller agaisn the moving conveyer for desired idler repair/replacement.

3. Online roller replacement equipment as claimed in anyone of claims 1 or 2 comprising
a base frame to provide stable support to the equipment when removably installed on conveyor platform for roller replacement purpose;
a roller rotatably mounted on a shaft to provide load support to conveyor with low resistance to movement;
a turn buckle with adjustable screw pivoted at one end on a first bracket fixed at front end of the base frame, for lifting and lowering of said roller with shaft;
a guide block mounted on said roller shaft pivoted on a second bracket fixed at rear end of the base frame to enable length adjustment of roller shaft and provide trunion action;
a locking arrangement with wing nut for locking the adjusted length of the roller shaft;
other end of said turn buckle with adjustable screw is pivotally connected to the opposite end of said roller shaft such that when the turn buckle is rotated with respect to the adjustable screw, overall length of the turn buckle is extended or shortened and accordingly the angle of inclination of the roller with shaft is increased or decreased depending on clockwise or anticlockwise direction of rotation of the turn buckle to gradually provide load support to the moving conveyor or make it free of load as per need and to create required gap to favour replacement of damaged idler with spare.

4. Online roller replacement equipment as claimed in anyone of claims 1 to 3 wherein position of roller with respect to width of conveyor is adjusted by adjusting the length of the roller shaft between the pivot points at front and rear end by unlocking the wing nut and moving the shaft forward or backward through guide block and finally locking the nut after correct position is reached with the equipment placed under the conveyor beside any damaged idler to be replaced.

5. Online roller replacement equipment as claimed in anyone of claims 1 to 4 which is adapted to replace damaged roller in any trough angle conveyor having width in the range of preferably 1 m, subjected to variable load.

6. Online roller replacement equipment as claimed in anyone of claims 1 to 5 wherein the diameter of roller shaft is selected so that buckling of shaft is avoided during online replacement of damaged idler.

7. Online roller replacement equipment as claimed in anyone of claims 1 to 6 wherein the length of the turn buckle and the roller shaft is adjustable between the respective pivot points to favour positioning of roller with respect to conveyor belt width and also loading/unloading of conveyor load on roller.

8. A method of replacement of damaged idler roller of trough angle conveyor involving the roller replacement equipment as claimed in claims 1 to 7 comprising
(i) reducing the angle of the online roller replacement arrangement by adjusting the turn buckle with adjustable screw;
(ii) placing the online roller replacement equipment on its base frame on conveyor platform under the running conveyor belt keeping gap between roller and conveyor belt;
(iii) adjusting the position of the roller of the equipment in relation to conveyor width by using the guide block and locking the correct position using wing nut of the locking arrangement.
(iv) adjusting the length of turn buckle with adjustable screw by rotating the turn buckle so that roller of online roller replacement equipment takes the load of the running belt and adjustment is continued untill the load was taken completely by the equipment and a gap is created between the damaged idler and conveyor which becomes free of load of running conveyor belt to enable damaged idler replacement.
(v) replacing the damaged idler with a spare new one.
(vi) gradually releasing the load of running conveyor belt from the equipment and transferring the same to replaced idler roller and creating a gap between the equipment and the conveyor belt by adjusting turn buckle until the replaced idler roller starts working.
(vii) finally releasing the online roller replacement equipment from conveyor and removing from the work site.

9. A method as claimed in claim 8, wherein the angle of the online roller replacement arrangement can be increased or decreased by adjusting the turn buckle with adjustable screw to lift or lower the running belt to release load on damaged idler or take load on replaced spare idler.

10. A method as claimed in anyone of claims 7 or 8, wherein the roller replacement equipment is temporarily used during replacement of damaged idlers in online mode.

11. A method as claimed in anyone of claims 7 to 10, wherein one person is enough to replace any damaged idler comfortably with very less effort and time.
Dated this the 31st day of March, 2015
Anjan Sen
Of Anjan Sen & Associates
(Applicants Agent)

ABSTRACT

TITLE: ONLINE ROLLER REPLACEMENT EQUIPMENT FOR SELECTIVE IDLER REPAIR/REPLACEMENT FROM MOVING TROUGH CONVEYORS.

The present invention relates to an online roller replacement equipment for online replacement of damaged idler roller of trough angle conveyor. The online roller replacement equipment comprises a combination of components like link, turn buckle, roller, base, trunion, guide block and lock arrangement configured in such a way that it is compact and easy to handle and also favour easy replacement of damaged idler roller of any trough angle conveyor in online mode. The roller of the equipment can be positioned in relation to the width of the conveyor and the load of conveyor can be released from damaged idler to roller for replacement and transferred back to the replaced spare roller. The equipment is designed for easy handling of any trough angle conveyor’s carrying damaged idlers changing operation with less manpower without stopping the conveyor, thus reducing down time and increasing plant availability.
(Figure 4)