Air-supported belt conveyors and systems and methods of using same

An air-supported belt conveyor system having a longitudinal axis and comprising:

• a conveyor belt having a longitudinal length and a curved cross-sectional profile;
• a plurality of trough sections positioned along the longitudinal length of the conveyor belt, each trough section being positioned under the conveyor belt and defining at least one opening for receiving air to support the conveyor belt above a top surface of each trough section;
• an air delivery subsystem comprising:
• at least one air supply, line;
• and
• a plurality of air manifolds positioned in fluid communication with the at least one air supply line, wherein each air manifold contacts a single trough section and is in fluid communication with at least one opening of the single trough section;
• a plurality of flow control valves, wherein each flow control valve is positioned in fluid communication with at least one air manifold and the at least one air supply line and is configured to permit selective adjustment of air flow to the at least one air manifold from the at least one air supply line;
• and
• a plurality of branch conduits, wherein each branch conduit extends between the at least one air supply line and at least one air manifold, wherein a portion of the plurality of flow control valves are each positioned in fluid communication with a respective branch conduit;
• a processor communicatively coupled to each flow control valve and configured to adjust a position of each flow control valve to selectively control delivery of air to the at least one opening of each respective trough section through the plurality of air manifolds and thereby support the conveyor belt;
• a plurality of sensors, wherein each sensor is communicatively coupled to the processor, wherein each sensor is selected from the group consisting of a pressure sensor, a flow sensor, and combinations thereof, wherein at least a portion of the plurality of sensors are each positioned in fluid communication with a respective branch conduit and configured to produce an output indicative of a fluid pressure or flow rate within the respective branch conduit, and wherein the processor is configured to receive the output from each sensor of said portion of sensors and to selectively control the plurality of flow control valves to adjust air flow to the manifold positioned in fluid communication with the respective branch conduit,
• wherein adjacent trough sections of the plurality of trough sections are not sealingly connected.