# US 11,440,745 B2 · Apparatus and method for monitoring conveyor systems

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- Number: US 11,440,745 B2
- Document ID: US11440745B2
- Status: Granted
- Kind: B2
- Application number: 17/099,411
- Filed: 2020-11-16
- Published: 2021-06-17
- Granted: 2022-09-13
- Earliest claimed: 2017-12-22
- Assignees: Flexible Steel Lacing Company
- Applicants: Flexible Steel Lacing Company
- Inventors: Brett E. DeVries; Todd A. Zeilinger; Kurt Alan Dykema; David Adrian Moelker
- Web page: https://patentgrep.com/patent/US11440745B2

## CPC

- B65G 45/12: comprising scrapers
- B65G 43/00: Control devices, e.g. for safety, warning or fault-correcting
- B65G 43/02: detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
- B65G 45/16: with scraper biasing means
- G01M 13/00: Testing of machine parts
- G01M 13/028: Acoustic or vibration analysis
- B65G: TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS (packaging B65B; handling thin or filamentary materials, e.g. paper sheets or thread, B65H; cranes B66C; portable mobile or lifting or hauling appliances, e.g. hoists, B66D; devices for lifting or lowering goods for loading or unloading purposes, e.g. fork-lift trucks, B66F9/00; emptying bottles, jars, casks, barrels or similar containers, not otherwise provided for, B67C9/00; delivering or transferring liquids B67D; filling or discharging vessels for liquefied, solidified or compressed gases F17C; pipe-line systems for fluids F17D)
- G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR

## Abstract

In one aspect, an apparatus is provided for a conveyor belt system. The apparatus includes a conveyor belt cleaner having an elongate support and a pair of mounts configured to position the elongate support to extend across a conveyor belt. The apparatus includes a cleaner blade configured to be operatively mounted to the elongate support and engage a conveyor belt. The apparatus further includes a sensor configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation. A processor of the apparatus is configured to use the at least one characteristic of the elongate support to predict at least one property of the cleaner blade.

## Claims

### Claim 1

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a c-shaped member having ends separated by a gap, the ends of the c-shaped member facing one another across the gap;
the c-shaped member extending about an opening sized to receive an elongate support of the conveyor belt cleaner and permit the c-shaped member to be mounted on the elongate support;
a sensor operatively mounted to the c-shaped member and configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation;
communication circuitry operatively mounted to the c-shaped member, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub.

### Claim 2 (depends on 1)

The apparatus of claim 1 wherein the c-shaped member includes an inner annular surface extending about the opening to contact an outer surface of the elongate support.

### Claim 3 (depends on 1)

The apparatus of claim 1 wherein the c-shaped member includes an inner surface extending about the opening, the apparatus further comprising:
a clamp operable to engage the inner surface of the c-shaped member with an outer surface of the elongate support and secure the c-shaped member to the elongate support.

### Claim 4 (depends on 1)

The apparatus of claim 1 wherein the at least one characteristic includes a position of the elongate support.

### Claim 5 (depends on 1)

The apparatus of claim 1 wherein the sensor is configured to detect a change in position of the elongate support.

### Claim 6 (depends on 1)

The apparatus of claim 1 wherein the sensor is configured to detect a rotary distance the elongate support travels.

### Claim 7 (depends on 1)

The apparatus of claim 1 in combination with the communication hub, the communication hub configured to communicate with a remote computer via a wireless network.

### Claim 8 (depends on 1)

The apparatus of claim 1 further comprising a battery operatively connected to the sensor and the communication circuitry.

### Claim 9 (depends on 1)

The apparatus of claim 1 further comprising at least one indicator.

### Claim 10 (depends on 1)

The apparatus of claim 1 further comprising a temperature sensor; and
wherein the communication circuitry is operable to communicate data associated with a temperature detected by the temperature sensor to the communication hub.

### Claim 11

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a housing;
an opening of the housing sized to receive an elongate support of the conveyor belt cleaner and permit the housing to be mounted on the elongate support;
a sensor in the housing configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation;
communication circuitry in the housing, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub;
wherein the housing includes a sleeve portion extending about the opening, the sleeve portion having a pair of ends separated by a gap; and
a clamping member operable to narrow the gap and clamp the sleeve portion on the elongate support.

### Claim 12

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a housing;
an opening of the housing sized to receive an elongate support of the conveyor belt cleaner and permit the housing to be mounted on the elongate support;
a sensor in the housing configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation;
communication circuitry in the housing, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub;
wherein the housing comprises a compartment having at least one wall, a door for being connected to the at least one wall and closing the compartment, and a plurality of fasteners for securing the door to the at least one wall.

### Claim 13

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a housing;
an opening of the housing sized to receive an elongate support of the conveyor belt cleaner and permit the housing to be mounted on the elongate support;
a sensor in the housing configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation;
communication circuitry in the housing, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub; and
wherein the data associated with the at least one characteristic of the elongate support is received by a remote computer configured to estimate a remaining lifespan of a cleaner blade of the conveyor belt cleaner.

### Claim 14

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a sensor module configured to be mounted on an elongate support of the conveyor belt cleaner;
a clamp portion of the sensor module having an inner surface to engage an outer surface of the elongate support, the clamp portion of the sensor module including a threaded member and a nut, the clamp portion configured to clamp the inner surface of the sensor module against the outer surface of the elongate support and secure the sensor module to the elongate support upon tightening of the nut and the threaded member together so that the sensor module moves with the elongate support during conveyor belt operation;
a sensor of the sensor module configured to detect at least one characteristic of the elongate support; and
communication circuitry of the sensor module, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub.

### Claim 15 (depends on 14)

The apparatus of claim 14 wherein the clamp portion of the sensor module includes a sleeve portion having an opening to receive the elongate support.

### Claim 16 (depends on 14)

The apparatus of claim 14 wherein the at least one characteristic includes a position of the elongate support.

### Claim 17 (depends on 14)

The apparatus of claim 14 wherein the sensor is configured to detect a change in a position of the elongate support.

### Claim 18 (depends on 14)

The apparatus of claim 14 wherein the sensor is configured to detect a rotary distance the elongate support travels.

### Claim 19 (depends on 14)

The apparatus of claim 14 wherein the clamp portion of the sensor module includes a band for securing the sensor module to the elongate support.

### Claim 20 (depends on 14)

The apparatus of claim 14 in combination with the communication hub, the communication hub configured to communicate with a remote computer via a wireless network.

### Claim 21 (depends on 14)

The apparatus of claim 14 wherein the sensor module includes a battery to provide power to the sensor and the communication circuitry.

### Claim 22 (depends on 14)

The apparatus of claim 14 wherein the sensor module includes a temperature sensor; and
wherein the communication circuitry is operable to communicate data associated with a temperature detected by the temperature sensor to the communication hub.

### Claim 23

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a sensor module configured to be mounted on an elongate support of the conveyor belt cleaner;
a clamp portion of the sensor module configured to engage an outer surface of the elongate support and secure the sensor module to the elongate support so that the sensor module moves with the elongate support during conveyor belt operation;
a sensor of the sensor module configured to detect at least one characteristic of the elongate support;
communication circuitry of the sensor module, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub; and
wherein the clamp portion of the sensor module includes a pair of clamping surface portions having an initial configuration wherein the clamping surface portions permit the elongate support to be received therebetween and a clamping configuration wherein the clamping surface portions engage outer surface portions of the outer surface of the elongate support and clamp the elongate support between the clamping surface portions.

### Claim 24 (depends on 23)

The apparatus of claim 23 wherein the clamp portion of the sensor module has an inner surface configured to extend about the elongate support and the pair of clamping surface portions comprise a pair of inner surface portions of the inner surface that are across the elongate support from each other for clamping the elongate support therebetween in the clamping configuration.

### Claim 25 (depends on 24)

The apparatus of claim 24 wherein the inner surface is arcuate for clamping a cylindrically configured elongate support member.

### Claim 26 (depends on 23)

The apparatus of claim 23 wherein the clamp portion of the sensor module comprises a sleeve portion having an opening to receive the elongate support, the sleeve portion including the pair of clamping surface portions extending about the opening.

### Claim 27 (depends on 26)

The apparatus of claim 26 wherein the sleeve portion of the sensor module includes a pair of ends separated by a gap, wherein the clamp portion includes a clamping member operable to narrow the gap.

### Claim 28 (depends on 23)

The apparatus of claim 23 wherein the clamp portion of the sensor module includes a C-shaped member comprising the pair of clamping surface portions.

### Claim 29 (depends on 23)

The apparatus of claim 23 wherein the sensor is configured to detect a change in a position of the elongate support.

### Claim 30 (depends on 23)

The apparatus of claim 23 wherein the sensor is configured to detect a rotary distance the elongate support travels.

### Claim 31 (depends on 23)

The apparatus of claim 23 wherein the clamp portion of the sensor module includes a band for securing the sensor module to the elongate support.

### Claim 32 (depends on 23)

The apparatus of claim 23 in combination with the communication hub, the communication hub configured to communicate with a remote computer via a wireless network.

### Claim 33 (depends on 23)

The apparatus of claim 23 wherein the sensor module includes a battery to provide power to the sensor and the communication circuitry.

### Claim 34 (depends on 23)

The apparatus of claim 23 wherein the sensor module includes a temperature sensor for detecting temperature; and
wherein the communication circuitry is operable to communicate data associated with the detected temperature to the communication hub.

### Claim 35

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a sensor module configured to be mounted on an elongate support of the conveyor belt cleaner;
a clamp portion of the sensor module having an inner surface to engage an outer surface of the elongate support, the clamp portion of the sensor module configured to clamp the inner surface of the sensor module against the outer surface of the elongate support and secure the sensor module to the elongate support so that the sensor module moves with the elongate support during conveyor belt operation;
a sensor of the sensor module configured to detect at least one characteristic of the elongate support;
communication circuitry of the sensor module, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub;
wherein the clamp portion of the sensor module includes a sleeve portion having an opening to receive the elongate support; and
wherein the sleeve portion of the sensor module includes a pair of ends separated by a gap, wherein the clamp portion includes a clamping member operable to narrow the gap and secure the sensor module on the elongate support.

### Claim 36

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a sensor module configured to be mounted on an elongate support of the conveyor belt cleaner;
a clamp portion of the sensor module having an inner surface to engage an outer surface of the elongate support, the clamp portion of the sensor module configured to clamp the inner surface of the sensor module against the outer surface of the elongate support and secure the sensor module to the elongate support so that the sensor module moves with the elongate support during conveyor belt operation;
a sensor of the sensor module configured to detect at least one characteristic of the elongate support;
communication circuitry of the sensor module, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to a communication hub; and
wherein the clamp portion of the sensor module includes a C-shaped member.

### Claim 37

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a single, unitary body configured to be mounted to an elongate support of the conveyor belt cleaner;
a sensor carried by the body and configured to detect at least one characteristic of the elongate support;
communication circuitry carried by the body, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to an external device; and
inner surface portions of the body having an initial configuration wherein the inner surface portions permit the elongate support to be received therebetween and a clamping configuration wherein the inner surface portions clamp an outer surface of the elongate support therebetween so that the body moves with the elongate support during conveyor belt operation.

### Claim 38 (depends on 37)

The apparatus of claim 37 wherein the body has an opening sized to receive the elongate support; and
wherein the inner surface portions of the body extend about the opening.

### Claim 39 (depends on 37)

The apparatus of claim 37 wherein the body has an opening sized to receive the elongate support;
wherein the body has a gap that opens to the opening and extends away from the elongate support with the elongate support received in the opening; and
wherein the inner surface portions of the body are disposed opposite each other on either side of the gap.

### Claim 40 (depends on 37)

The apparatus of claim 37 wherein the body has an inner annular surface; and
wherein the inner annular surface of the body comprises the inner surface portions of the body.

### Claim 41 (depends on 37)

The apparatus of claim 37 wherein the body has a circular opening to receive the elongate support; and
wherein the inner surface portions of the body are diametrically opposed from one another across the opening for clamping the elongate support therebetween in the clamping configuration.

### Claim 42 (depends on 37)

The apparatus of claim 37 further comprising a clamping member operable to shift the clamping surface portions from the initial configuration to the clamping configuration.

### Claim 43 (depends on 42)

The apparatus of claim 42 wherein the clamping member includes a band.

### Claim 44 (depends on 37)

The apparatus of claim 37 further comprising a threaded member and a nut operably connected to the body; and
wherein tightening the nut and the threaded member together shifts the inner surface portions of the body from the initial configuration to the clamping configuration.

### Claim 45 (depends on 37)

The apparatus of claim 37 wherein the body has a pair of ends separated by a gap;
wherein the ends of the body are separated by a first distance with the clamping surface portions in the initial configuration; and
wherein the ends of the body are separated by a second distance that is less than the first distance with the clamping surface portions in the clamping configuration.

### Claim 46 (depends on 37)

The apparatus of claim 37 in combination with the conveyor belt cleaner having at least one cleaning blade;
the apparatus further comprising a processor configured to identify wear of the at least one cleaner blade based at least in part upon the at least one characteristic of the elongate support.

### Claim 47 (depends on 37)

The apparatus of claim 37 further comprising a battery operatively connected to the sensor and the communication circuitry.

### Claim 48 (depends on 37)

The apparatus of claim 37 further comprising a temperature sensor for detecting temperature; and
wherein the communication circuitry is operable to communicate data associated with the detected temperature to the external device.

### Claim 49 (depends on 37)

The apparatus of claim 37 in combination with the external device, wherein the external device is a communication hub or an apparatus for monitoring another conveyor belt cleaner.

### Claim 50 (depends on 37)

The apparatus of claim 37 wherein the communication circuitry is configured to wirelessly communicate the data to the external device.

### Claim 51

An apparatus for monitoring a conveyor belt cleaner, the apparatus comprising:
a body configured to be mounted to an elongate support of the conveyor belt cleaner;
a sensor carried by the body and configured to detect at least one characteristic of the elongate support;
communication circuitry carried by the body, the communication circuitry configured to communicate data associated with the at least one characteristic of the elongate support to an external device; and
a clamp connected to the body and having an actuator operable to cause the clamp to deform the body and clamp the body to the elongate support.

### Claim 52 (depends on 51)

The apparatus of claim 51 wherein the clamp includes a threaded member and a nut threadingly engaged with the threaded member.

### Claim 53 (depends on 51)

The apparatus of claim 51 wherein the actuator is rotatable to cause the clamp to deform the body.

### Claim 54 (depends on 51)

The apparatus of claim 51 wherein the body has an inner surface portion to engage the elongate support and an outer surface portion opposite the inner surface; and
wherein the clamp has a clamp inner surface portion configured to engage the outer surface portion of the body and deform the body.

### Claim 55 (depends on 51)

The apparatus of claim 51 wherein the body comprises inner surface portions having an initial configuration wherein the inner surface portions permit the elongate support to be received therebetween and a clamping configuration wherein the inner surface portions clamp the elongate support therebetween; and
wherein the clamp is operable to shift the inner surface portions from the initial configuration to the clamping configuration by deforming the body.

### Claim 56 (depends on 51)

The apparatus of claim 51 wherein the body includes ends separated by a gap, the ends facing one another across the gap; and
wherein the clamp is operable to narrow the gap by deforming the body.

### Claim 57 (depends on 51)

The apparatus of claim 51 wherein the clamp includes clamp portions on opposite sides of the body; and
wherein the actuator is operatively connected to the clamp portions and operable to shift the clamp portions together to deform the body.

### Claim 58 (depends on 51)

The apparatus of claim 51 wherein the body is configured to separate the clamp from the elongate support with the body mounted to the elongate support.

### Claim 59 (depends on 51)

The apparatus of claim 51 wherein the clamp includes a band.

### Claim 60 (depends on 51)

The apparatus of claim 51 in combination with the conveyor belt cleaner; and
wherein the at least one characteristic includes a position of the elongate support.

### Claim 61 (depends on 51)

The apparatus of claim 51 in combination with the external device, wherein the external device is a communication hub or an apparatus for monitoring another conveyor belt cleaner.

### Claim 62 (depends on 51)

The apparatus of claim 51 wherein the communication circuitry is configured to wirelessly communicate the data to the external device.

### Claim 63 (depends on 51)

The apparatus of claim 51 further comprising a faceplate having a user interface.

### Claim 64 (depends on 51)

The apparatus of claim 51 wherein the elongate support has a length, the apparatus further comprising elongate cylindrical batteries operatively connected to the sensor and the communication circuitry to provide power to the sensor and the communication circuitry; and
wherein the elongate cylindrical batteries each have a length oriented to extend parallel to the length of the elongate support with the body mounted to the elongate support.

### Claim 65 (depends on 51)

The apparatus of claim 51 further comprising:
a circuit board; and
elongate cylindrical batteries carried by the body and operatively connected to the sensor and the communication circuitry to provide power to the sensor and the communication circuitry; and
wherein the elongate cylindrical batteries each have a central axis parallel to a plane of the circuit board.