AU2017216448B2 - An apparatus and a method for lifting a conveyor belt - Google Patents

Abstract

The present disclosure relates to an apparatus for lifting a belt of a belt conveyor, the apparatus comprising: a body that is movable along the belt conveyor; a belt lifting element connected to the body and configured to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller of the belt conveyor; and at least one supporting element connected to the body and configurable in at least a travel position in which the apparatus can move along the belt conveyor, and a lifting position in which the at least one supporting element engages with a frame of the belt conveyor such that a load exerted from lifting the belt section by the belt lifting element is directly transferred to the frame of the belt conveyor. 1/19 Ln -) CI .4 roT

Description

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"An apparatus and a method for lifting a conveyor belt"

Technical Field

[0001] The present invention relates to an apparatus and a method for lifting a conveyor belt, for example to replace an idler roller of the belt conveyor.

Background

[0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0003] Belt conveyors are generally used for material handling and transportation. In particular, belt conveyors are commonly used for transportation of particulate materials, for example, in mining and grain-handling applications.

[0004] A belt conveyor typically comprises an endless conveyor belt passing around end rollers to define an upper load-carrying run and a lower return run. The upper and lower runs are supported at intervals by a series of sets of idler rollers. Each roller set usually includes two or more idler rollers disposed in an end-to-end relation and positioned to engage the underside of the respective run effectively distributing a downward force of the conveyor belt between them. Where the load carrying run is of trough configuration, the idler roller sets each typically comprises a horizontal central roller and two inclined side rollers on opposite ends of the central roller arranged to guide the trough configuration of the belt between them.

[0005] There may be a need to change an idler roller over time, for example when an idler roller is faulty or defect. The replacement procedure, which is sometimes referred to as roller change-out, typically entails stopping the conveyor, isolating any energy sources, gaining access to the idlers rollers by, for example, lifting the section of the conveyor belt at which the defective idler roller is located from the rollers, removing and replacing the defective idler roller, and then returning the lifted section of the conveyor belt to the original position so that it is supported on the replacement roller. In certain circumstances, it may also be necessary to remove the material being carried on the conveyor belt in order to access the idler rollers of the belt conveyor.

[0006] Accordingly, it is often necessary that operation of the belt conveyor be stopped so that the belt is not moving while an idler roller is replaced. This can lead to significant losses, both in terms of time and production opportunities. For example, in a mining environment, transportation of material on a belt conveyor may translate to thousands of dollars per hour, with a stoppage of any number of minutes equating to significant losses.

[0007] Further, the removal and replacement of the idler roller is typically performed manually. This can be disadvantageous as it requires use of specifically trained personnel, can also be time consuming, and may expose personnel to hazardous working positions. Where an idler roller is exchanged manually, stopping of the conveyor belt is particularly important, as it forms a major safety concern for the personnel performing the roller replacement.

Summary

[0008] In accordance with some embodiments of the present disclosure, there is provided an apparatus for lifting a belt of a belt conveyor, the apparatus comprising:

a body that is movable along the belt conveyor;

a belt lifting element connected to the body and configured to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller of the belt conveyor; and at least one supporting element connected to the body and configurable in at least a travel position in which the apparatus can move along the belt conveyor, and a lifting position in which the at least one supporting element engages with a frame of the belt conveyor such that a load exerted from lifting the belt section by the belt lifting element is directly transferred to the frame of the belt conveyor.

[0009] In an embodiment, the apparatus comprises at least one pair of supporting elements that is arranged such that the supporting elements engage with the frame of the belt conveyor on substantially opposite sides of the belt conveyor when the supporting elements are in the lifting position.

[0010] The at least one supporting element maybe pivotably connected to the body of the apparatus. In this embodiment, the at least one supporting element is configurable between the travel position and the lifting position by pivoting the at least one supporting element relative to the body.

[0011] The apparatus may comprise an actuator for moving the supporting element between the travel position and the lifting position. The actuator may for example comprise a hydraulic arm.

[0012] The at least one supporting element comprises abase portion for engaging with the frame of the belt conveyor wherein the base portion extends along a longitudinal stringer of the frame. The base portion of the at least one supporting element may have a length that is shorter than a distance between two sets of idler rollers, substantially equal to a distance between two sets of idler rollers, or longer than a distance between two sets of idler rollers.

[0013] The apparatus may comprise a locking element arranged to lock the at least one supporting element in the lifting position when the belt lifting element lifts the belt section of the belt. The locking element may be implemented by the actuator described above.

[0014] The apparatus may comprise a release element arranged to automatically move the at least one supporting element from the lifting position to the travel position when lifting of the belt section has been completed. The release element may comprise a spring. The release element may alternatively be implemented by the actuator described above.

[0015] In an embodiment, the belt lifting element comprises a belt support configurable between an engaged position in which the belt support engages with the belt such that the belt section can be lifted, and a disengaged position in which the apparatus can move along the belt conveyor.

[0016] The belt lifting element maybe arranged to lift the belt section by raising the belt support. In addition, the belt lifting element may be arranged to subsequently lower the lifted belt support such that the belt section is supported by the at least one idler roller.

[0017] The belt support may comprise at least one support arm configured to support an underside of the belt when the belt support is in the engaged position. In a specific embodiment, the belt support may comprise a pair of support arms. The pair of support arms may extend in substantially opposite directions such that the belt can be supported from substantially opposite sides of the belt.

[0018] In an embodiment, the belt support maybe arranged such that moving the belt support from the disengaged position to the engaged position causes movement of the at least one supporting element from the travel position to the lifting position. For example, an end portion of a carrier arm may be arranged to cause pivoting of the at least one supporting element.

[0019] The belt support may comprise one or more rollers such that when the belt section is lifted by the belt lifting element, the belt can continue moving.

[0020] In an embodiment, the belt lifting element may comprise at least one lifting actuator to actuate lifting of the belt section. The lifting actuator may comprise a lift arm that is extendable to lift the belt section such that a space is provided between the lifted belt section and at least one idler roller. In one embodiment, the lifting actuator may comprise a hydraulic arrangement to extend and retract the lift arm.

[0021] The at least one lifting actuator maybe arranged such that extending the lift arm causes movement of the at least one supporting element from the travel position to the lifting position. For example, the at least one supporting element may comprise a socket for receiving an end portion of the lift arm when the supporting element is configured in the lifting position. The at least one lifting actuator may additionally be arranged that extending the lift arm causes locking of the at least one supporting element in the lifting position.

[0022] In an embodiment, the apparatus may be arranged such that the at least one supporting element automatically moves from the lifting position to the travel position when the belt lifting element moves from the engaged position to the disengaged position. For example, the at least one supporting element may automatically move from the lifting position to the travel position when the end portion of the lift arm disengages with the at least one supporting element.

[0023] In an alternative embodiment, the body of the apparatus may comprise wheels such that the apparatus is moveable along a surface of the belt. In this embodiment, the belt of the belt conveyor may be stopped and cleared from material that is transported on the belt, such that the apparatus can move along the surface of the belt.

[0024] The apparatus may further be arranged such that lifting the belt section of the belt by the belt lifting element causes the body of the apparatus to rise.

[0025] In an embodiment, the apparatus comprises a sensor configured to detect an idler roller of the belt conveyor that may need replacement, such as a defect idler roller. For example, the sensor may be configured to detect a property of the idler roller that is indicative of malfunctioning of the idler roller. The sensor may comprise at least one of: a thermal sensor, an acoustic sensor and a vibration sensor.

[0026] In an embodiment, the apparatus may comprise a roller replacement element configured to replace an idler roller of the belt conveyor when a belt section is lifted by the belt lifting element. The apparatus may be configured such that the roller replacement element replaces an idler roller in an automated or semi-automated manner. The roller replacement element may comprise a robotic arm.

[0027] In an embodiment, the belt conveyor comprises an endless conveyor belt and a plurality of idler rollers spaced apart to support the endless conveyor belt.

[0028] In accordance with some embodiments of the present disclosure, there is provided a method of lifting a belt of a belt conveyor, the method comprising:

providing an apparatus for lifting a belt of a belt conveyor, the apparatus being moveable along the belt conveyor;

moving a belt lifting element of the apparatus from a disengaged position to an engaged position in which the belt lifting element supports the belt to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller of the belt conveyor; and

moving at least one supporting element of the apparatus from a travel position in which the apparatus can move along the belt conveyor to a lifting position in which the at least one supporting element engages with a frame of the belt conveyor such that a load exerted from lifting the belt section is directly transferred to the frame; and

lifting the belt section by the belt lifting element when the belt lifting element is in the engaged position and the at least one supporting element is in the lifting position.

[0029] The at least one supporting element of the apparatus may move from the travel position to the lifting position after the belt lifting element moves from the disengaged position to the engaged position.

Brief Description of Drawings

[0030] Exemplary embodiments of the present invention are more fully described in the following description. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which like numerals refer to like parts throughout:

Figure 1 is a schematic perspective view of an apparatus for performing an idler roller replacement operation on a belt conveyor having a conveyor belt supported on a series of idler rollers in accordance with an embodiment of the present invention;

Figure 2 is a top view of the apparatus of Figure 1;

Figure 3 is a side view of the apparatus of Figure 1, showing the apparatus in position on the belt conveyor;

Figure 4 is a cross-sectional view along line A-A of Figure 3, showing the apparatus in more detail;

Figure 5 is a side view of the apparatus, showing a belt lifting assembly engaging a section of the conveyor belt;

Figure 6 is a cross-sectional view along line B-B of Figure 5, showing the belt lifting assembly engaging the conveyor belt in more detail;

Figure 7 is a side view of the apparatus, showing a belt lifting assembly lifting a section of the conveyor belt;

Figure 8 is a cross-sectional view along line C-C of Figure 7, showing the belt lifting assembly lifting the conveyor belt in more detail;

Figure 9 is a side view of the apparatus, showing a belt lifting assembly lifting a section of the conveyor belt and a mechanism for replacing an idler roller in operation;

Figure 10 is a cross-sectional view along line D-D of Figure 9, showing the belt lifting assembly lifting the conveyor belt and the mechanism for replacing an idler roller in operation in more detail;

Figure 11 is a schematic perspective view of an apparatus for lifting a belt of a belt conveyor in accordance with a further embodiment of the present invention;

Figure 12 is a cross-sectional view of the apparatus of Figure 11 while the belt lifting element is in disengaged position;

Figure 13 is a further cross-sectional view of the apparatus of Figure 11 while the belt lifting element is in engaged position;

Figure 14 is a further cross-sectional view of the apparatus of Figure 11 when the belt lifting element has lifted the belt;

Figure 15 is a side view of the apparatus of Figure 11 in position on the belt conveyor;

Figure 16 is a side view of the apparatus of Figure 11 with the belt lifted;

Figure 17 is a schematic view of an apparatus in accordance with a further embodiment of the present invention;

Figure 18 is a schematic perspective view of the apparatus of Figure 17; and

Figure 19 shows a flow chart illustrating a method of lifting a belt of a belt conveyor.

Description of Embodiments

[0031] The following description provides examples of different embodiments of apparatus for lifting a belt of a belt conveyor, for example for replacing an idler roller of the belt conveyor. Features that are common to the art are not explained in any detail as they are deemed to be easily understood by the skilled person.

[0032] The described apparatus may find application in performing a roller replacement of an idler roller of the belt conveyor 11. This is particularly applicable for a belt conveyor 11 of the type that has an endless conveyor belt 13 passing around end rollers (not shown) to define an upper load carrying run 15 and a lower return run 17. For this particular type, the upper run 15 is typically supported at intervals by a set of upper idler rollers 19, and the lower run 17 is supported at intervals by a set of lower idler rollers 20. In the exemplary arrangements shown in the Figures, the upper load carrying run 15 is of trough configuration, and each set of upper idler rollers 19 supporting the trough configuration comprises a horizontal central roller 21 and two inclined side rollers 23 on lateral sides of the central roller 21. The idler rollers 21 and 23 are supported in roller support cradles 25 mounted on a frame 27 of the belt conveyor 11. The frame 27 is of a type well-known in the art and includes longitudinal stringers 29 extending along the length of the belt conveyor 11 on opposite sides thereof. The conveyor 11 may also include a belt tie-down component 38, as for example shown in Figure 4, which is used to secure the belt 13 on the conveyor 11, for example during strong weather conditions.

[0033] Replacement of an idler roller such as an upper idler roller 19 typically involves lifting a section of the upper run 15 of the conveyor belt 13 from a defective roller, removing the defective roller, installing a replacement roller, and then lowering the lifted section of the upper run 15 so that the section is supported by the replacement roller. In some cases, more than one idler roller may be replaced at any one time.

[0034] Referring now to Figure 1, there is shown an apparatus 100 in accordance with a first embodiment of the present invention for lifting a belt 13 of a belt conveyor 11 such that replacement of an idler roller that supports the belt 13 can be facilitated. One particular advantage of this particular embodiment of the apparatus 100 is that replacement of the idler roller can be performed whilst the belt 13 of the conveyor 11 is in motion to continue conveying material on the belt 13.

[0035] The apparatus 100 has a body 40 that is movable along the belt conveyor 11 and that can be positioned such that a belt section of the belt 13 can be lifted, for example for replacing one or more idler rollers that support the belt section.

[0036] In this particular embodiment, the body 40 of the apparatus 100 comprises a front portion 41 and a rear portion 42 that are linked together by a linkage 43, as shown in Figure 1. The front portion 41 supports a belt lifting element 50 mounted on the body 40. The belt lifting element 50 is operable to engage the conveyor belt 13 to lift the belt 13 from, and subsequently lower said belt 13 onto, idler rollers 19 operatively supporting the belt 13 of the conveyor 11.

[0037] The rear portion 42 supports ancillary equipment, including a propulsion system 31 for propelling the apparatus 100 along the belt conveyor 11, a power supply 35 for providing energy to the apparatus 100, as well as sensing and control equipment 36, which will be described in more detail below. It will be appreciated that other embodiments may feature different configurations and positioning of components. For example, the apparatus may have an integrally formed frame structure that forms the body of the apparatus as exemplarily shown in Figures 11 to 16.

[0038] The apparatus 100 according to the embodiment is typically arranged to replace an idler roller in an automated manner. To achieve this, the apparatus 100 in this example comprises a sensor for sensing defective idler rollers or that detect a property of the roller that is indicative of excessive wear or malfunctioning of the roller. Such sensor may for example be implemented by a thermal imaging camera for sensing higher-than-normal roller bearing temperatures, a vibration sensor for sensing abnormal vibrations of the rollers during operation, an acoustic sensor for sensing faulty roller operation, and/or any sensor that is able to detect a suitable property of the roller.

[0039] In this example, the apparatus 100 further comprises a controller for controlling operation of the apparatus. The controller may for example be configured to move the apparatus 100 along the conveyor 11 whilst sensing for rollers that may require replacement and, if a roller is detected that requires replacement, to control the belt lifting element 50 to lift a section of the belt 13 off the detected idler roller. The controller may further be configured to control a roller replacement element 95 to perform replacement of the roller.

[0040] As shown in Figure 1, the body 40 of the apparatus 100 is arranged to straddle the belt conveyor 11. In this example, the apparatus 100 is able to move along the belt conveyor 11 by virtue of wheels 37 that engage with a track 32 that extends along both longitudinal stringers of the frame 27. The track 32 is incorporated within the belt conveyor 11 and forms part of the frame 27. However, it will be appreciated that the track 32 may form a separate component that may for example be retrospectively added to the belt conveyor 11. Furthermore, it will be appreciated that the apparatus 100 may be moveable along the belt conveyor 11 without the need of a track. Such an arrangement will be exemplarily described with reference to apparatus 300 shown in Figure 17.

[0041] The apparatus 100 comprises a drive (not shown) for moving the apparatus 100 along the track 32. The drive comprises any suitable drive mechanism, such as a drive unit connected to at least some of the wheels 37, and is energised via the power supply 35, which may include any suitable power supply, such as a generator, electrochemical cells, and photovoltaic cells.

[0042] The apparatus 100 may include a securing element (not shown) which maybe part of the wheels 37 for securing the apparatus 100 to the track 32. A suitable securing element may include a rack and pinion arrangement, a mechanical detent or brake mechanism configured to engage and secure the apparatus 100 to the track 32 or the frame 27 of the belt conveyor 11. The securing element may for example secure the apparatus 100 to the track 32 when the belt lifting element 50 lifts a belt section of the belt 13. In addition, a securing element may provide additional operational stability where the apparatus 100 is operating on an uneven belt conveyor 11, such as replacing a roller on an incline/decline.

[0043] In this example, the body 40 of the apparatus 100 comprises a frame structure including a side frame structure 44 and an overhead frame structure 45, as exemplarily shown in Figure 3. The side frame structure 44 and the overhead frame structure 45 may be of integral construction. The overhead frame structure 45 comprises a series of spaced transverse overhead beams 47 and a central overhead beam 48 supported by the transverse beams 47 to form a suitable framework for supporting the belt lifting element 50. A frame structure as described above that straddles the belt conveyor may be particularly advantageous in avoiding collision with the belt tie-down 38 which is standard on many outdoor conveyors.

[0044] The belt lifting element 50 mounted to the above described frame structure 44 is configured to lift a section of the conveyor belt 13 at intervals along the length thereof, as best seen in Figure 7 in which the lifted section of the belt 13 is identified by reference numeral 13a. A section of the belt 13 may be lifted to different extents along the length thereof to provide a relatively smooth transition between the lifted section 13a of the conveyor belt 13 and adjacent sections 13b thereof that are not being lifted. This may be advantageous if the conveyor belt 13 carries particularly heavy material, or if the belt 13 moves at relatively high speed.

[0045] In the example apparatus 100 shown in Figures 1 to 10, the belt lifting element 50 is configured to lift a section of the conveyor belt 13 at two lifting locations depicted in Figure 7 as locations 51 and 54. However, it will be appreciated that in order to provide an even smoother transition between the lifted section 13a and adjacent sections 13b, the belt 13 may be lifted at additional lifting locations to different heights. It will also be appreciated that the belt lifting element 50 may be configured to lift a section of the conveyor belt 13 at only one lifting location, as for example described with reference to apparatus 200 shown in Figures 11 to 16.

[0046] The belt lifting element 50 comprises a belt support 61 as for example shown in Figure 4. In this example, the belt support 61 comprises two pairs of carrier arms 68 such that the belt 13 can be lifted at two respective lifting locations. The pair of carrier arms 68 is configured to move between an engaged position for engaging the upper run 15 of the conveyor belt 13 to lift and lower the conveyor belt 13 and a disengaged position in which the carrier arms 68 are clear from the conveyor belt 13. The apparatus comprises a hydraulic power unit 31 that is arranged to provide power to actuator 90 which will further be described below.

[0047] In Figures 1 to 4, the carrier arms 68 are depicted in the disengaged position clear from the belt. In this position, the apparatus 100 is free to move along the belt 13 without interference by the belt lifting element 50.

[0048] Figures 5 and 6 show the carrier arms 68 in the above mentioned engaged position in which the carrier arms 68 move towards each other such that the belt sections that is to be lifted is supported by the carrier arms 68. Each carrier arm 68 comprises a support section 63 arranged to engage with an underside of the upper run 15 of the belt 13 to support the belt 13 while the belt section is lifted. The support sections 63 are mounted on a carrier 65 which comprises the pair of carrier arms 68. The carrier arms 68 are disposed on opposite sides of the belt 13, each carrying one of the support sections 63.

[0049] Each carrier arm 68 is mounted for pivotal movement between the engaged position and the disengaged position for moving the support section 63 into and out of a position below the underside of the upper run 15 of the conveyor belt 13. In the engaged position, the carrier arms 68 position the respective support sections 63 below the underside of the upper run 15, as shown in Figure 6. In the disengaged position, the carrier arms 68 position the respective support sections 63 clear from the conveyor belt 13. Thus, the belt support 61 functions like a claw that grasps around the belt 13 to lift a belt section off the idler rollers 19.

[0050] As best shown in Figures 4 and 6, each support section 63 generally comprises first and second supporting elements 71 and 72, wherein the first supporting element 71 is adapted to support an adjacent marginal edge portion 15a of the upper run 15 of the conveyor belt 13, and the second supporting element 72 is adapted to support a central section 15b of the upper run 15 of the conveyor belt 13. In this example, the supporting elements 71 and 72 are implemented as rollers. This provides the particular advantage of facilitating lifting and lowering of the conveyor belt 13 while the conveyor belt 13 is still in motion. Consequently, an idler roller 19 of the belt conveyor 11 may be replaced without the need of stopping the belt 13.

[0051] In this particular example, each carrier arm 68 comprises a plurality of arm sections 80 disposed in end-to-end angular relation. The carrier arm 68 comprises an first arm section 81 at which the carrier arm 68 is pivotally mounted at pivot 79 to the central overhead beam 48 of the overhead frame structure 45, as best seen in Figures 4 and 6. The carrier arm 68 further comprises a second arm section 82 connected to the first arm section 81. As shown, the carrier arm 68 further comprises third and fourth arm sections 83, 84. Still further, the arm section 80 includes an intermediate arm section 85 between the two arm sections 82 and 84.

[0052] The apparatus 100 further comprises an actuator 90 that is provided to actuate the carrier arms 68 between the engaged and disengaged positions. The disengaged position is shown best in Figure 8 in which the carrier arms 68 support the belt 13 to lift a belt section from the idler rollers 21 and 23. In this example, the actuator 90 is operably connected to the pair of carrier arms 68 to actuate the carrier arms 68 for pivotal movement between the engaged and disengaged positions. The actuator 90 comprises a first hydraulic arm 93 operable between the carrier arms 68, wherein extension and retraction of the hydraulic arm 93 causes pivotal movement of the carrier arms about the pivots 79 between the engaged and disengaged positions. In the arrangement shown, the first hydraulic arm 93 is further connected to a second hydraulic arm 94. Extension and retraction of this second hydraulic arm 94 raises and lowers the carrier arms 68 when the carrier arms 68 are in the engaged position in order to lift the belt 13 from the rollers 21 and 23.

[0053] As mentioned, each pair of carrier arms 68 is mounted for displacement vertically when in the operative position to facilitate movement of the supporting elements 71 and 72 into and out of engagement with the underside of the upper run 15 of the conveyor belt 13, and also lifting and lowering the conveyor belt 13. As shown in Figures 6 to 8, this is accomplished by the second hydraulic arm 94 which selectively raises and lowers the respective pivots 79. With this arrangement, the carrier arms 68 in each pair of carrier arms would be raised and lowered in unison.

[0054] The apparatus 100 further comprises a roller replacement element 95 for replacing an idler roller of the belt conveyor 11. In the exemplary embodiment shown in Figures 1 to 10, the roller replacement element 95 comprises a robotic arm 97 mounted on the body 40. In this example, the robotic arm 97 is of articulated construction and autonomous, but may also be remote controlled or have a semi autonomous configuration. The robotic arm 97 has an end portion 99 configured as a gripping element for handling idlers rollers and performing roller replacement operations. Figures 9 and 10 show the robotic arm engaging an idler roller 23 for replacement.

[0055] The robotic arm 97 is arranged to access the central roller 21 and side rollers 23 in a target upper roller set 19 once the conveyor belt 13 has been lifted from the roller set. In one example, the robotic arm 97 may be configured to operate from a fixed position mounted on the body 40 of the apparatus 100 with sufficient reach to access any of the rollers 21 and 23. In an alternative example, the robotic arm 97 may be mounted on the body 40 in a way such that the robotic arm 97 can move into a variety of positions to facilitate access to any of the rollers 21 and 23. In the latter example, the robotic arm 97 may for example be mounted on a turntable of rail (not shown) facilitating travel of the robotic arm 97 from one side of the conveyor belt 15 to the other, thereby facilitating access to any of the rollers 21 and 23.

[0056] In this particular example, the apparatus 100 further includes an active roller nest 33 on the front portion 41 of the body 40, which is readily accessible by the robot arm 97 to replace rollers. The apparatus 100 also includes additional spare roller nests 34 on the rear portion 42, as for example shown in Figure 1, for storing additional replacement or used rollers. However, it will be appreciated that any replacement rollers or used rollers may be stored remotely from the apparatus 100.

[0057] It will be appreciated that the apparatus 100 may be arranged to be permanently installed on the belt conveyor 11 or may be installed on the belt conveyor 11 as required when a roller change-out operation is to be performed. When an idler roller needs replacement, the apparatus 100 is moved along the belt conveyor 11 to a position at which there is an idler roller requiring replacement. The sensing system 36 may be configured to detect imminent roller failure or defective roller operation using sensors (not shown) that may be positioned on vertical sections of the frame 44, as described above. The power input device 90 is actuated to move the carrier arms 68 from the disengaged position into the engaged position, thereby moving the support sections 63 into position on the underside of the upper run 15 of the belt 13 from opposite sides thereof. The carrier arms 68 are then displaced vertically to lift the conveyor belt 13 from the roller set 19. The roller configuration of the support sections 63 allows the conveyor belt 13 to continue to move, and to perform its load-carrying function, while supported in the lifted position. Once the conveyor belt 13 has been lifted, the robotic arm 97 can be deployed to perform the necessary replacement of the idler roller 19. Once the idler roller 19 has been replaced, the carrier arms 68 are lowered to return the conveyor belt 13 into its supported position on the idler roller set 19. The power input device 90 is actuated to return the carrier arms 68 to the disengaged position such that the apparatus 100 can freely move along the belt conveyor11.

[0058] Referring now to Figures 11 to 16, there is shown a further embodiment of an apparatus 200 for lifting a belt section of a conveyor belt 13. We note that in the embodiment shown in Figures 11 to 16, like numerals refer to like parts as exemplarily illustrated for apparatus 100.

[0059] Similar to apparatus 100, the apparatus 200 comprises a body 40 that is movable along the belt conveyor 11. The body 40 in this particular embodiment comprises a frame structure that supports a belt lifting element 50 configured to lift a section of the belt 13. In this particular embodiment, the frame structure of the body 40 is significantly more compact than the body 40 of the apparatus 100. Due to the arrangement of providing supporting elements as further described below, it is possible to design the frame structure in a more lightweight manner and optionally build it in integral form. Instead of linking the front portion 41 and the rear portion 42 by a linkage 43, all components of the apparatus 200 are supported by one frame structure.

[0060] The body 40 of the apparatus 200 is configured to straddle the conveyor belt 13 and can be moved along the belt conveyor 11 by virtue of wheels 37 that engage with a track 32. In this example, the track 32 is extruded and comprises a pair of rails that are attached to opposite sides of the belt conveyor 11, as for example shown in Figure 11. The track 32 may be permanently installed at the conveyor 11 or removable if desired. In this regard, the body 40 is shaped and the apparatus 200 is configured to provide the significant advantage that the apparatus 200 may be applicable to new and existing belt conveyors 11 of any structural arrangement.

[0061] The frame structure of the body 40 further supports a roller replacement element 95 which in this example is implemented as a robotic arm 97. In order to replace an idler roller 19, 20 of the belt conveyor 11, the body 40 of the apparatus 200 may have an opening such that the robotic arm 97 can move to a position in which any of the idler rollers 19, 20 including the idler rollers 20 supporting the lower return run 17 of the conveyor belt 13, can be accessed and if necessary replaced.

[0062] The belt lifting element 50 is configured to lift a section of the conveyor belt 13 such that a space is provided between the lifted belt section and at least one idler roller 19 that supports the upper run 15 of the conveyor belt 13. In this way, a defect or faulty idler roller 19 may be replaced using the robotic arm 97.

[0063] Similar to apparatus 100, the belt lifting element 50 of the apparatus 200 comprises a pair carrier arms 68 that are pivotably connected via respective pivots 79 to the frame structure 40. The belt lifting element 50 can be configured in an engaged position and a disengaged position as described above with respect to apparatus 100. Specifically, when the belt lifting element 50 is in the engaged position, the pair of carrier arms 68 pivots towards each other in a claw-like manner such that the carrier arms 68 support an underside of the belt section that is to be lifted. The carrier arms 68 can then be raised to lift the belt section of the belt 13.

[0064] The carrier arms 68 have a plurality of arm sections wherein some arm sections support rollers 71 and 72 such that when the belt section of the belt 13 is lifted by the belt lifting element 50, the belt 13 of the conveyor 11 can continue to move and carry material along the conveyor 11.

[0065] The apparatus 200 further comprises at least one supporting element 202 connected to the body 40 of the apparatus 200 and configurable in at least a travel position and a lifting position. In this particular example, the apparatus 200 comprises a pair of supporting elements 202, 204 positioned on opposite sides of the body 40 of the apparatus 200. When the pair of supporting elements 202, 204 is in the travel position, the supporting elements 202, 204 are clear from the frame 27 of the conveyor 11 such that the apparatus 200 can freely move along the belt conveyor 11. This position is, for example, shown in Figure 12.

[0066] When the pair of supporting elements 202, 204 is in the lifting position, both supporting elements 202, 204 engage with a portion of the frame 27 of the belt conveyor 11 such that a load exerted from lifting the belt section by the belt lifting element 50 is directly transferred to the frame of the belt conveyor 11. The lifting position is, for example, shown in Figures 11, 13 and 14.

[0067] The arrangement of providing the supporting elements 202, 204 in this embodiment provides significant advantages. In particular, by directly transferring the load that is exerted from lifting the belt section to the frame 27 of the conveyor 11, the body 40 of the apparatus 200 may be manufactured in a more lightweight manner than an apparatus without the supporting elements 202, 204. This is due to the fact that the requirement for providing structural robustness of the body 40 is reduced.

[0068] For an apparatus without the supporting elements 202, 204, the load exerted from lifting the belt section would typically be transferred through the frame structure of the apparatus through the wheels 37 and the track 32 on which the apparatus and then to the conveyor frame 27. As such, an apparatus without the supporting elements 202, 204 would require more structural robustness and a heavier frame construction of the body 40 to withstand the force exerted by the belt lifting. This requirement can be lowered by including the supporting elements 202, 204 that directly transfer the force to the frame 27 of the conveyor.

[0069] In addition, the load exerted from lifting the belt section is no longer transferred to the track 32 of the apparatus 200 and can therefore be unloaded. As a consequence, the track 32 may be manufactured in a lighter manner and extruded form since the load exerted by the lifting of the belt 13 is not transferred through the track 32, but directly from the supporting elements 202, 204 to the conveyor frame 27. Thus, the costs for manufacturing the apparatus 200 may be significantly reduced. Furthermore, installation of the apparatus on the conveyor 11 may be simplified and therefore a reduction of costs for the installation may be achieved.

[0070] In this particular embodiment, the supporting elements 202, 204 of the apparatus 200 are pivotably connected to opposite sides of the frame structure of the body 40. Thus, the supporting elements 202, 204 can be moved from the travel position to the lifting position (and vice versa) by pivoting the supporting elements 202,

204 relative to the frame structure. A person skilled in the art will appreciate that the supporting elements 202, 204 may alternatively or additionally be translated to move between the travel position and the lifting position.

[0071] The supporting elements 202, 204 have abase portion that is sized such that the load exerted from lifting the belt section can be directly transferred to the conveyor frame 27. In one particular example as shown in Figures 11 to 16, the supporting elements 202, 204 have respective base portions for engaging with the conveyor frame 27 wherein each base portion extends along a longitudinal stringer of the conveyor frame 27. In some belt conveyors, the conveyor frame 27 has a plurality of longitudinal stringers that have gaps in between. For example, each longitudinal stringer may have a length of 11 m with a gap of 0.5 m between each of them. In this particular example, the base portions have a length that is shorter than a distance between two sets of idler rollers 19, but longer than the gap between the longitudinal stringers such that the gap may be bridged by the base portion if the supporting element engages with the frame at that particular position. However, it will be appreciated that any form, shape or length of the supporting elements 202, 204 and its base portions is envisaged such that a force from the belt lifting element 50 can be directly transferred to the conveyor frame 27.

[0072] In general, the form and shape of the supporting elements 202, 204 may depend on a number of factors. These factors may include the size of the conveyor, the weight of the conveyor belt, the weight of the material to be transported by the conveyor belt, the structure of the conveyor frame, the location of the idler rollers and the like.

[0073] The apparatus 200 may be arranged such that the supporting elements 202, 204 are pivoted between the travel position and the lifting position in an automated manner. In this particular example as shown in Figures 11 to 16, the apparatus 200 comprises a further actuator (not shown) that is configured to pivot the supporting elements 202, 204 from the travel position to the lifting position and from the lifting position to the travel position. The actuator may for example comprise a hydraulic arm or any other suitable actuating mechanism.

[0074] In other examples (not shown), the supporting elements 202, 204 may be caused to move from the travel position towards the lifting position by virtue of the belt lifting element 50. In particular, an end portion of each of the carrier arms 68 moves the supporting elements 202, 204 at least partially from the travel position to the lifting position, when the carrier arms 68 move from the disengaged position to the engaged position. For this, the end portion of each of the carrier arms 68 engages with the supporting elements 202, 204 to cause pivoting of the supporting elements 202, 204.

[0075] In the embodiment shown in Figures 11 to 16, the belt lifting element 50 further comprises a pair of lifting actuators 206, 208 to actuate lifting of a belt section of the belt 13. Each lifting actuator 206, 208 comprises a hydraulic arm that is extendable and retractable, and lifting of the belt section is actuated by extending the hydraulic arms of the respective lifting actuators 206, 208. In particular, when the carrier arms 68 are moved from the disengaged position to the engaged position, and thereafter the supporting elements 202, 204 are moved from the travel position to the lifting position, the hydraulic arms of the lifting actuators 206, 208 extend, engage with the supporting elements 202, 204 and extend further to lift the belt section of the belt 13, as shown best in Figures 13 and 14.

[0076] As shown in the Figures, the supporting elements 202, 204 each comprises a socket 210, 212 for receiving an end portion of an hydraulic arm of the lifting actuators 206, 208. As such, the supporting elements 202, 204 are locked in the lifting position when the lifting actuators 206, 208 raise and subsequently lower the belt lifting element 50.

[0077] In addition, it will be appreciated that in an exemplary arrangement, the belt lifting element 50 may be arranged such that an end portion of the hydraulic arms of the lifting actuators 206, 208 cause the supporting elements 202, 204 to pivot from the travel position to the lifting position.

[0078] The apparatus 200 may further comprise a locking element that is arranged to lock the supporting elements 202, 204 in the lifting position when the belt lifting element 50 lifts the belt section of the belt 13. In the embodiment as shown in Figures 11 to 16, the end portions of the hydraulic arms of the lifting actuators 206, 208 provide this function when the end portions engage with the supporting elements 202, 204. However, it will be appreciate that a separate locking element may be provided.

[0079] The apparatus 200 may further comprise a release element (not shown) that is arranged to automatically or semi-automatically move the supporting elements 202, 204 from the lifting position to the travel position such that the apparatus 200 can move along the belt conveyor 11. Such release element may for example be implemented by the actuator mentioned above. For example, the actuator may be actuated when the hydraulic arms of the lifting actuators 206, 208 retract, or when the carrier arms 68 of the belt lifting element 50 move to the disengaged position. Alternatively, the release element may comprise a spring that is arranged to automatically move the supporting elements 202, 204 from the lifting position to the travel position when the ends of the lifting actuators disengage.

[0080] As mentioned above, the apparatus 200 comprises a roller replacement element 95 which in this example is implemented as a robotic arm 97. As shown in particular in Figures 15 and 16, the robotic arm 97 is supported on the frame of the body 40 and can move such that any of the idler rollers 19 can be accessed and replaced when the belt section of the belt 13 is lifted by the belt lifting element 50.

[0081] It should be noted that the robotic arm 97 of the roller replacement element 95 is also configured to replace an idler roller 20 that supports the lower return run 17 of the conveyor belt 13. It will be appreciated that the method of lifting a belt section of the lower return run 17 is similar to lifting of a belt section of the load carrying run of the belt 13.

[0082] Referring now to Figures 17 and 18, there is shown an apparatus 300 in accordance with a further embodiment of the present invention.

[0083] The apparatus 300 has a body 340 that is moveable along the belt conveyor 11. However, in this particular example, the apparatus 300 comprises wheels 342 that are arranged such that the apparatus 300 can move on a top surface of the upper run 15 of the belt 13 as exemplarily shown in Figure 17. In order to move the apparatus 300 along the belt 13, a person skilled in the art will appreciate that it may be required to stop the belt 13 from moving, and to clear the belt 13 from any remaining material that is transported on the belt 13. In addition, the belt may be isolated such that tension of the belt is reduced or entirely removed.

[0084] In Figure 17, the upper load carrying run 15 of the belt 13 has a trough like arrangement. As such, the body 340 of the apparatus 300 may comprise wheels 342 that engage with the centre portion of the belt 13 and guide wheels 344 that engage with the inclined portions of the belt 13 to provide sufficient stability when the apparatus 300 moves along the belt conveyor 11. However, it will be appreciated that the guide wheels 344 are optional.

[0085] The apparatus 300 further comprises a belt lifting element 350 that can be configured in an engaged position and a disengaged position, and a pair of supporting elements 302, 304 that are configurable in a travel position and a lifting position as described with reference to apparatus 200.

[0086] In this example, the belt lifting element 350 comprises a pair of a carrier arms 352. Each of the carrier arms comprises a clamping element 354 that is arranged to clamp side edges of the belt section 15a that is to be lifted. As such, when the belt lifting element 350 is in the engaged position, the clamping elements 354 of the carrier arms 352 clamp the side edge of the belt section 15a such that the belt section 15a can be lifted. A person skilled in the art will appreciate that the belt lifting element 350 may include any suitable number of carrier arms. For example, the belt lifting element 350 may comprise two pairs of carrier arms such that a larger section 15a of the belt 13 can be lifted.

[0087] In order to move the belt lifting element 350 from the disengaged position to the engaged position, each carrier arm 352 pivots about a pivot 356 to position the clamping elements 354 in proximity and around the side edges of the belt 13. The clamping elements 354 are then actuated to secure the side edges within the clamping elements 354 as shown schematically by dotted lines in Figure 17. A person skilled in the art will appreciate that any suitable actuating mechanism is envisaged for actuating the clamping elements 354.

[0088] In order to lift the belt section 15a, the apparatus 300 further comprises a pair of lifting actuators 306, 308 similar to lifting actuators 206, 208 of apparatus 200. Each of the lifting actuators 306, 308 is connected to the supporting elements 302, 304 that are arranged to engage with the conveyor frame 27 such that a load exerted by lifting the belt section 15a is directly transferred to the conveyor frame 27.

[0089] In this particular example, each of the lifting actuators 306, 308 is pivotably connected to the carrier arms 352 such that when the carrier arms 352 move into the engaged position, the lifting actuators 306, 308 can extend such that the supporting elements 302, 304 engage with the frame as indicated by dotted lines in Figure 17. By further extending the lifting actuators 306, 308, the whole apparatus 300 is lifted relative to the conveyor frame 27 thereby lifting the belt section 15a.

[0090] Similar to apparatus 100 and 200, the apparatus 300 further comprises a roller replacement element comprising a robotic arm for replacing idler rollers 19 supporting not only the upper load carrying run 15 of the belt 13, but also idler rollers 20 supporting the return run 17 of the conveyor belt 13.

[0091] With regard to the idler rollers 20 supporting the return run 17 of the conveyor belt 13, the apparatus 300 may lift a belt section of the return run 17 of the belt 13 as described above. However, it should be noted that, alternatively, for lifting the return run 17 of the belt 13, the supporting elements 302, 304 may not be required to engage with the conveyor frame 27. Instead, the supporting elements 302, 304 may also have clamping elements that can be actuated similar to the clamping elements 354 of the carrier arms 352. As such, the lifting actuators 306, 308 may extend such that the supporting elements 302, 304 can clamp onto side edges of the return run 17 of the belt 13. In order to lift a belt section of the return run 17 of the belt 13, the lifting actuators 306, 308 are subsequently retracted while the body 340 of the apparatus 300 remains stationary on top of the belt 13.

[0092] Referring now to Figure 19, there is shown a flow chart illustrating a method 400 of lifting a belt of a belt conveyor, for example for replacing an idler roller supporting the conveyor belt. The method comprises a step 402 of providing an apparatus for lifting a belt of a belt conveyor, wherein the apparatus is moveable along the belt conveyor. The apparatus may for example be implemented by exemplary apparatus 200.

[0093] In a further step 404, a belt lifting element of the provided apparatus is moved from a disengaged position to an engaged position in which the belt lifting element supports the belt to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller supporting the belt of the belt conveyor.

[0094] In addition, at least one supporting element of the apparatus is moved 406 from a travel position in which the apparatus can move along the belt conveyor to a lifting position in which the at least one supporting element engages with a frame of the belt conveyor such that a load exerted from lifting the belt section is directly transferred to the frame.

[0095] When the belt lifting element is in the engaged position and the at least one supporting element is in the lifting position, the method further comprises a step of lifting 408 the belt section by the belt lifting element.

[0096] It should be appreciated that the scope of the invention is not limited to the scope of the embodiment described. Various modifications and improvements may be made to the embodiment described without departing from the scope of the invention.

[0097] While the embodiment has been described in relation to performance of an idler roller change-out operation on a belt conveyer which is in operation, it should be understood that the apparatus may also be used to perform a roller change-out operation while the conveyor belt is stationary.

[0098] Further, while the embodiment has been described in relation to performance of an idler roller change-out operation on idler roller sets supporting an upper run of a belt conveyer, it should be understood that it the apparatus may also be used to perform a roller change-out operation on idler roller sets supporting a lower run of a belt conveyer

[0099] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

[0100] It is to be appreciated that reference to "one example" or "an example" of the invention is not made in an exclusive sense. Accordingly, one example may exemplify certain aspects of the invention, whilst other aspects are exemplified in a different example. These examples are intended to assist the skilled person in performing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise.

[0101] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

List of reference numerals

100 Apparatus

11 Belt conveyor 13 Conveyor belt or belt 13a lifted section of the belt, 13b adjacent not lifted sections of the belt

15 upper load carrying run, 15a marginal edge portion of upper load carrying run 15b central section of upper load carrying run 17 lower return run

19, 20, 21, 23 idler rollers 21 central roller 23 inclined side rollers 25 support cradles (for supporting rollers) 27 frame (conveyor frame) 29 longitudinal stringers (of the frame)

31 hydraulic power unit 32 track (spidler track) 33 active roller nest 34 spare roller nest power supply 36 sensing and control equipment 37 wheels 38 belt tie-down mechanism

40 body 41front portion 42 rear portion 43 linkage 44 side frame structure 45 overhead frame structure 47 overhead beams 48 central overhead beam

50 belt lifting element 51, 54 lifting locations

61 belt support 63 support sections carrier 68 carrier arms

71, 72 supporting elements of each support section 63, supporting elements configured as rollers

79 pivot arm section 81 innermost arm section 82 arm section 83 outermost arm section 84 arm section intermediate arm section

actuator 93 hydraulic arm 94 second hydraulic arm roller replacement element 97 robotic arm 99 end portion

200 Apparatus 202 first supporting element 204 second supporting element 206 first lifting actuator 208 second lifting actuator 210 first socket 212 second socket

300 Apparatus 302 first supporting element 304 second supporting element 306 first lifting actuator 308 second lifting actuator 340 body 342 wheels 344 guide wheels 350 belt lifting element 352 carrier arms 354 clamping elements 356 pivot

Claims (16)

CLAIMS:

1. An apparatus for lifting a belt of a belt conveyor, the apparatus comprising:

a body;

a plurality of wheels connected to the body and configured to engage with a track extending along a frame of the belt conveyor such that the body is movable along the belt conveyor;

a belt lifting element connected to the body and configured to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller of the belt conveyor; and

at least one pair of supporting elements connected to the body and configurable in at least a travel position in which the apparatus can move along the belt conveyor, and a lifting position in which the supporting elements engage with the frame of the belt conveyor on substantially opposite sides of the belt conveyor, wherein the apparatus is configured such that when the supporting elements are in the lifting position and the belt lifting element lifts a section of the belt, a load exerted from lifting the belt section by the belt lifting element is directly transferred via the supporting elements to the frame of the belt conveyor.

2. The apparatus of claim 1, wherein each supporting element is pivotably connected to the body of the apparatus such that the supporting elements are configurable between the travel position and the lifting position by pivoting the supporting elements relative to the body.

3. The apparatus of any one of the preceding claims, wherein each supporting element comprises a base portion for engaging with the frame of the belt conveyor wherein the base portion extends along a longitudinal stringer of the frame.

4. The apparatus of any one of the preceding claims, wherein the belt lifting element comprises a belt support configurable between an engaged position in which +1,-b11+ - + - -,+ +1, - ~ ±1- 1'+1+1,-b1-+ n -b40UI 44-A -~A disengaged position in which the apparatus can move along the belt conveyor.

5. The apparatus of claim 4 wherein the belt lifting element is arranged to lift the belt section by raising the belt support.

6. The apparatus of claim 4 or 5, wherein the belt support is arranged such that moving the belt support from the disengaged position to the engaged position causes movement of the at least one supporting element from the travel position to the lifting position.

7. The apparatus of claim 6, wherein the belt support comprises at least one support arm and an end portion of at least one carrier arm is arranged to cause moving

the at least one supporting element from the travel position to the lifting position.

8. The apparatus of any one of the preceding claims, wherein the belt lifting element comprises at least one lifting actuator to actuate lifting of the belt section, the lifting actuator comprising a lifting arm that is extendable to lift the belt section such that a space is provided between the lifted belt section and at least one idler roller.

9. The apparatus of claim 8, wherein the lifting actuator comprises a hydraulic arrangement to extend and retract the lifting arm.

10. The apparatus of claim 8 or 9, wherein the at least one lifting actuator is arranged such that extending the lift arm causes movement of the at least one supporting element from the travel position to the lifting position.

11. The apparatus of any one of claims 8 to 10 wherein the at least one supporting element comprises a socket for receiving an end portion of the lift arm of the at least one lifting actuator when the supporting element is configured in the lifting position.

12. The apparatus of any one of claims 8 to 11, wherein the at least one lifting actuator is arranged such that extending the lift arm causes locking of the at least one supporting element when the supporting element is configured in the lifting position.

13. The apparatus of any one of the preceding claims, being arranged such that the at least one supporting element automatically moves from the lifting position to the travel position when the belt lifting element moves from the engaged position to the disengaged position.

14. The apparatus of any one of the preceding claims, comprising a roller replacement element configured to replace an idler roller of the belt conveyor when a belt section is lifted by the belt lifting element.

15. The apparatus of claim 16 wherein the apparatus is arranged such that lifting the belt section of the belt by the belt lifting element causes the body of the apparatus to rise.

16. A method of lifting a belt of a belt conveyor, the method comprising:

providing an apparatus for lifting a belt of a belt conveyor, the apparatus comprising a body being moveable along the belt conveyor by virtue of a plurality of wheels connected to the body and configured to engage with a track extending along a frame of the belt conveyor;

moving a belt lifting element of the apparatus from a disengaged position to an engaged position in which the belt lifting element supports the belt to lift a section of the belt such that a space is provided between the lifted belt section and at least one idler roller of the belt conveyor; and

moving a pair of supporting elements of the apparatus from a travel position in which the apparatus can move along the belt conveyor to a lifting position in which the supporting elements engage with a frame of the belt conveyor on substantially opposite sides of the belt conveyor; and is in the engaged position and the supporting elements are in the lifting position such that a load exerted from lifting the belt section is directly transferred via the supporting elements to the conveyor frame.