AU2016324340A1

AU2016324340A1 - An improved conveyor belt system

Info

Publication number: AU2016324340A1
Application number: AU2016324340A
Authority: AU
Inventors: Gary James
Original assignee: Craig James Ply Ltd
Current assignee: Craig James Ply Ltd
Priority date: 2015-09-18
Filing date: 2016-09-16
Publication date: 2018-03-29
Also published as: WO2017045012A1

Abstract

The present invention is a conveyor belt system having a carry section and a return section, and a continuous belt. The system including a foundation formed from slip formed concrete, for at least for the carry section, that enables rapid lineal construction of the foundation in situ. The conveyor system also includes a plurality of discreet idler roller support frames for the continuous belt, and each idler roller support frame supports at least one idler roller. Each discreet idler support frame includes a pair of feet, and each foot is connectable to a support pad assembly by way of fastening means, and once attached, the idler support frame is placed onto the foundation, whereat the support pad is fastened to the foundation, and the rate at which each idler support frame is fastened onto the foundation matches the rate of deployment of the foundation.

Description

The present invention is a conveyor belt system having a carry section and a return section, and a continuous belt. The system including a foundation formed from slip formed concrete, for at least for the carry section, that enables rapid lineal con struction of the foundation in situ. The conveyor system also includes a plurality of discreet idler roller support frames for the continuous belt, and each idler roller support frame supports at least one idler roller. Each discreet idler support frame includes a pair of feet, and each foot is connectable to a support pad assembly by way of fastening means, and once attached, the idler support frame is placed onto the foundation, whereat the support pad is fastened to the foundation, and the rate at which each idler support frame is fastened onto the foundation matches the rate of deployment of the foundation.

2017/045012

PCT/AU2016/000320

An Improved Conveyor Belt System

Field of the Invention

This invention relates to conveyor belt systems, and in particular to very high capacity long single flight conveyor belt systems and their method of construction and their maintenance.

Background of the Invention

The cost of materials handling is a significant factor in the viability of many mining, and other industrial operations. In addition to this, many mine operations require longer and higher capacity conveyor belt systems to move material from one location to another. As the distances increase, the cost of materials used to construct the support and optional roofing structure increases. The longer the distance that a conveyor belt system runs, the more power it requires to make it run. In addition to this, longer conveyor belt systems require more material, components, and construction time.

Typically, many long conveyor systems, for example up to 35km in length, often require multiple flights to keep individual flights within power supply limits, and their associated componentry within the range of items normally stocked by suppliers.

Also, many of these long conveyor belt systems traverse desolate terrain that may include arid or frozen landscapes. Many people are required to camp in these remote areas during the construction phase, often for many months at a time. The cost of sustaining these camps is substantial, and can adversely affect the economic viability of a project. Food, water, waste management, are all significant factors impacting the project viability. Any effort that reduces the overall construction and commissioning of the conveyor belt system greatly reduces the cost of these camps, and has a positive impact on the economic viability of the project.

2017/045012

PCT/AU2016/000320

Also projects with long construction phases may make it difficult to attract suitably qualified people to work under these remote and arduous conditions, and/or retain them for the duration of the construction phase of the project.

Longer conveyor belt systems, with higher capacity, also tend to utilize bulkier and heavier componentry to account for the power loss inherent in conveyor belt systems. This therefore requires correspondingly larger handling and lifting equipment at these remote construction sites. As an example, a 35km long conveyor system will likely include at least 60,000 idler rollers, and each roller will exceed the safe manual handling limit that a person can carry, thereby requiring special handling equipment.

At higher belt speeds and loads there is a higher risk of significant belt and structural system vibration. This can reduce the reliability and up time for the system, and may also generate significant noise that is environmentally unacceptable in some quiet environments. Another problem with vibration is payload clumping which may imbalance the system and create even worse vibration and noise in the system.

Finally, these structures are often exposed to the elements such as wind. Wind force can force sections of the long conveyor belt system to be forced out of proper alignment, particularly if the support foundation is light, and unable to adequately resist the wind load. It is also required, in many instances, that the payload is protected from the elements such as rain, so therefore a roof structure is built to cover the carry belt. The material used to construct the roof adds significantly to capital expenditure for the project. It also slows down the rate at which the conveyor belt system can be constructed. It will also likely raise the side profile of the conveyor belt system, and thereby make the conveyor system even more susceptible to the deleterious effects of wind load on the structure, particularly if that wind load acts over a wide area.

Conveyors are used in a number of applications, including mining, for moving bulk material from one location to another. Such conveyors typically include a long flexible looped belt onto which bulk material is loaded and driven by, for example,

2017/045012

PCT/AU2016/000320 drive pulley(s) at either or both ends, or multiple motorized rollers. Conveyors typically include a number of idler rollers spaced along the conveyor to form the belt into a trough and also to support the belt.

Idler rollers may be secured to a roller mount (which may also be referred to as a roller frame), either having a live shaft or a dead shaft, depending upon the application. Each roller mount is generally incorporated into a support structure. The support structure typically extends the length of the conveyor, at each side of the extents of the conveyor belt. The support structure is usually formed from steel, and has legs that are secured directly, or indirectly, to, for example, concrete sleepers. The support structure also includes horizontal longitudinal beams (stringers) at each side of the conveyor, which are secured to the legs. At least some roller mounts are secured to the stringers via cross beams of the roller mounts, while other roller mounts may be secured to the legs. The support structure often comprises a number of support structure modules, and the number of legs in each support structure module can vary, and can number two, four or more. In long or high conveyor systems, the support structure can require a large amount of steel in construction. The support structure and the conveyor system can, therefore, be very expensive to build.

Each roller mount generally secures a number of rollers, and together, the mount and rollers may be referred to as a roller cluster. A roller cluster, including rollers offset from each other, is on a single mount and roller clusters are separated from each other along the conveyor.

Importantly, the support structure is required to provide structural integrity along the conveyor so that the idler rollers and their respective mounts do not move out of position, for example, during operation when the conveyor is moving and carrying the bulk material. The structure must maintain the rollers accurately in position under high loads and resist vibration. Additionally, the support structure provides resistance to environmental conditions including gusts of wind, which can blow very forcefully against conveyors as they are often not shielded by other structures. The support structure therefore typically requires a substantial amount of extra material,

2017/045012

PCT/AU2016/000320 usually steel, to achieve the required strength and stiffness, which significantly increases the cost of a conveyor system.

The support structure, or each support structure segment, is typically supported on a foundation, which rests on the ground. The foundations (which, collectively, may be referred to as the foundation system) generally comprise a set of sleepers, bored piers or screw piles along a conveyor system.

Sleeper foundations in conjunction with the support structure used on present conveyors provide lateral and overturning resistance by a combination of mass, friction and or stakes, which are driven into the ground under the sleeper foundation. This configuration becomes inefficient as the size ofthe conveyor increases. As the conveyor size and its loads increase, sleepers struggle to provide sufficient stability against movement, or overturning caused by forces from the loaded, moving belt, and forces from winds, unless extra mass or stakes are added. Often, sleepers that form a foundation are supplied pre-formed to the location where a conveyor is constructed. The transportation costs for pre-formed foundations can be significant. The sleepers typically require an accurate surface or a fill layer, to allow good alignment and to prevent movement, and generally have a low coefficient of friction with the ground to resist sliding.

In one typical alternative, bored piers can provide a connection to the ground to resist the forces from the conveyor, wind, earthquakes, and other forces, internal to and external of, the conveyor system. However, bored piers are labour intensive and slow to install accurately and the costs can be significant. Bored piers can only be used if the ground is suitable for drilling. Another alternative is to pour concrete structures, which are similar to the sleepers. However, this may require some embedment in the ground, and is slow and costly to construct. Yet another means to prevent lateral movement of sleepers is to back fill around the sleepers. However, this means still has potential problems with overturning from wind and other sources of external forces.

2017/045012

PCT/AU2016/000320

Conveyor systems have a carry and a return section. The carry section is configured to support and move the belt to enable carrying of the load of bulk materials from a first end ofthe conveyor to a second end. The return section takes the emptied belt from the second end back to the first end to be re-loaded, in some conveyor configurations, the carry section is arranged above or below the return section with each section supported by the support structure. In other configurations, the carry section is arranged alongside the return section. In yet other conveyor systems, both sections are carry sections, wherein the return section also carries bulk material.

In some conveyor systems having side-by-side carry and return sections, the support may consist of two separate support structures, with each extending the entire, or substantially the entire length of the conveyor system. In other conveyor systems having a top-bottom arrangement of the carry and return section, the support is a single structure, which is higher than for the side-by-side arrangement, to support the stacked carry and return sections. The support structure therefore requires a large amount of steel, and is costly to construct, particularly in remote locations where mines are typically located. This extra cost in steel increases construction cost and time, and also requires transportation of the steel or other materials used in the construction ofthe support structure to remote locations.

Some installations include means for turning the belt over at either end of the conveyor in order that one face, being the carrying face, (dirty side) of the belt is always on the upper side both in the carry and return sections. This can be advantageous as the emptied belt may retain some carry back material which can enter into, for example, the bearings of the return section rollers if the carrying face of the belt is facing downward and in contact with the return idler rollers. The material can also cause roller shell wear or fall to the ground creating environmental problems, slip hazards and clean-up costs. The arrangement can also lower the power and tensions due to lower indentation losses.

The idler rollers are arranged on their respective mounts (together, a roller cluster) to force the flexible belt into a trough shape. The roller clusters are spaced intervals

2017/045012

PCT/AU2016/000320 or pitch(es), to support the belt along its length . This provides containment of bulk materials on the belt as well as preventing the belt from moving off the idler rollers. In a roller cluster, a number of idler rollers can be secured side-by-side on a roller mount which is shaped to provide a desired trough shape in the belt. Roller clusters can have two to five or more idler rollers placed on the same roller mount arranged in a substantially trough configuration. Typically, the trough outer wing angle of the carry section will be greater, as compared with the trough outer wing angle of the return section. Further, each roller mount of the return section typically has fewer rollers (for example, one, two or three) as compared with each roller mount of the carry section (for example, having two to five or more rollers on each mount). If there is a horizontal curve the return side may also have steeper or multiple wing rollers, or if some rollers are heavy, a number of lighter rollers may be used on both sides of the wing to reduce the manual handling weight.

In some conveyors, roller clusters have a number of idler rollers secured on each of the roller mounts, the rollers may be secured inline. In other conveyors, roller clusters have alternate rollers which are offset to either side of the roller mount. For example, in a five roller configuration, the two outer-most idler rollers and the central idler roller may be disposed on one side of the mount, with the other two idler rollers on the other side of the mount. In such arrangements, the rollers may not be completely offset, such that ends of inner-mounted rollers are eclipsed by outer-mounted rollers.

Conveyor systems have been increasing in length over time and the loads they are expected to carry are similarly increasing. Accordingly, the conveyor drive power requirement and belt strength for such installations approach and sometimes exceed the limit of a substantial amount of commonly available equipment, and belts if a single loop of conveyor belting is to be used (a series of belt lengths spliced together into a single loop). Customized solutions are very expensive and take time to design and install. One solution is to break up long conveyor systems into shorter conveyor lengths (which may also be referred to as flights), which allows use of the commonly available equipment, belts and drives. However, this solution leads to the problems of extra expense for the multiple conveyors, along with a need to transfer the load

2017/045012

PCT/AU2016/000320 material from one conveyor to another. Alternatively, tripper drives may be added at interval(s) along the conveyor system. These alternatives cause higher capital and maintenance costs and possible downtime with blockages and component wear or failure. Furthermore, large overland conveyors have very high belt tensions. This requires very accurate building of the support structure and very accurate alignment of the idler rollers to limit the load on each of the idler rollers, and to ensure a reasonable roller bearing and belt life and reduce tensions and power. The required build accuracy increases the construction time and expense. Long or high lift, high capacity conveyors require very large diameter high capacity bend and drive pulleys. This adds to the complexity and cost of the supporting structures and maintenance activities.

Previous conveyors have used low rolling resistance rubber and large diameter idler rollers. Typically, the roller diameters were between 102 mm and. 152mm. This was increased to 178mm as the conveyor size increased. In recent years there has been a trend to use even larger roller diameters of 194mm or similar, to lower power consumption and reduce the required tension in the belt.

Unfortunately, increasing the diameter of the idler rollers introduces problems associated with manual handling during construction and maintenance. Currently, idler rollers from multiple roller clusters can exceed 35kg. Single return rollers can be even heavier. Recent occupational health and safety standards may require a weight limit in the idler rollers of 20kg to 25kg to be suitable for manual handling by a single person. Even these weight limits are large, but are often not complied with, as a conveyor may require a larger and, therefore, heavier roller than the specified limit. Even at these low limits, the lifting index LI, as calculated by the equations produced by the National Institute for Occupational Safety and Health (NIOSH), Ohio USA, typically will exceed the allowable value of 1.0, by several times. According to the NIOSH equations, a 35 kg load should be held close, touching the body at the hips, when standing to achieve a LI<1.0. Reaching out to install or remove rollers results in the NIOSH lift index LI being much greater than 1.0.

2017/045012

PCT/AU2016/000320

Due to the structure used in the conveyors, that is, the roller mounts and the support structure, it is typically necessary to manually swap out and swap in idler rollers when they need replacement. The rollers may be very heavy and the workers must reach a long way to access and move the rollers. The combination weight and required reach length is often outside recommended guidelines of NIOSH and others. Further, the eclipsing of inner- mounted rollers by outer-mounted rollers, or support structures, can restrict ready access to the inner-mounted rollers. Reaching into an inner zone, can place the maintenance person at risk of entanglement.

Recently, robotic systems or machines have been used to replace rollers, however, these are in their infancy, are expensive, and are not always effective. Also, systems have been developed to slide the roller mounts out sideways, to allow better access for lifting the rollers. However, these systems are very expensive and sideways movement can be resisted by friction from material spillage build-up, corrosion alignment, and other factors.

The roller mounts, and, in particular, the support structures, restrict access to the rollers by lifting equipment, as the rollers are located within, and behind, those structures in an installed conveyor system. The support structure is very large and would be extremely difficult to remove if access to the idler rollers by the lifting equipment is required. Further, the removed support structure must be replaced after roller maintenance. The removal and replacement of the support structure is very time-consuming and expensive.

Often the support structure is integral with other parts of the conveyor so that it cannot be readily removed, even if desired. Accordingly, manual maintenance has been a general requirement for servicing idler rollers in a conveyor system.

Idler rollers have been made with hollow shafts, or aluminium or composite roller shells, instead of steel, to reduce their weight. However, such rollers tend to have reduced capacities and can have shorter operational life due to shell wear. The currently available range of these alternative rollers is limited. Some conveyors have an increased number of rollers in each set, to reduce the weight of each roller,

2017/045012

PCT/AU2016/000320 for example, increasing from three rollers to five rollers in the carry section; and increasing from one roller to two or three rollers or more, respectively, in the return section. The conveyor system reliability is likely to be reduced as the number of rollers required in the system increases. Furthermore, roller bearings fail early due to ingress of dirt or loss of lubricant. Therefore, reducing the number of required parts is likely to reduce the failure rate.

Larger idler rollers, for example, 300mm rollers, have been discussed and investigated. However, roller diameters have remained in the range of 200mm due to the increased weight, making them unsuitable for manual handling. The weight of a 300mm roller may be in excess of 80kg, and therefore cannot be manually handled. Unfortunately, due to the support structures in conveyor systems, such heavy rollers cannot be readily accessed by lifting devices, or other devices.

Another problem for conveyors is vibration, which can be caused by the operation of the conveyor, via roller rotation, belt flap, bulk material load clumping, the wind, and other causes internal and external to the conveyor. The problem can be made worse by sympathetic vibration of the support structure. If there is alignment of the load frequency and the belt flap or structural frequency, the vibration can have a catastrophic effect on the conveyor.

There is a desire to increase the length and capacity of conveyors. One solution is to use increasingly higher belt strengths and larger drives. Belt strengths of 10,000 kN/m have recently been manufactured, and conveyors have used commonly available drive reducers to their limit. With conveyors having such large sizes, low speed motors without reducers become economically feasible. These high capacity, large items of equipment are very expensive, and are subject to very slow supply from suppliers.

Desired improvements in the construction and operation of conveyors include: reduction in number of moving parts; increase in speed of the conveyor belt; reduction in vertical loads; reduction in pressure between the belt and the idler rollers; reduction in tensions; reduction of belt strength requirements; increased

2017/045012

PCT/AU2016/000320 efficiency to save power in operating the conveyor; reduction in building costs; reducing steel and concrete quantities; reducing the risk of sympathetic structural vibration; speeding up the building time; simplifying the building process; simplifying and improving the safety of maintenance of the conveyor with respect to manual handling and, in . particular, with respect to manual handling of the idler rollers; increasing life expectancy of the idler rollers and belt; reducing the roller rotational speed; reducing the risk of roller bearing lubricant loss; reducing noise; reducing indentation loss of the belt over the rollers; reducing rotational drag of the idler rollers including seal drag and bearing drag; and increasing the length and capacity of conveyors, increasing roller shell wear life.

However, due to complex interdependencies between various elements of conveyor systems, it has not been possible to achieve all of these desired improvements using current technology. Improvements have been very minor, or incremental, for example, by extending existing standards, and by making belts stronger, drives bigger and support structures heavier, and belt safety factors lower.

Generally, it has been found that changing one element requires corresponding changes in one or more other elements, thus rendering a change as problematic. For example, increasing the belt length or capacity requires more power and higher tensions to transmit the power at the drive pulley(s) without slip. Higher tensions require stronger, heavier belts, having thicker rubber covers, which require more power to move, leading to even higher required tensions. Higher tensions may be partially offset by increasing the belt speed, however, increasing belt speed increases the roller rotational speed, which increases the roller rotational drag, belt tensions, along with increased required belt strength and power. Increasing rotational speed of rollers reduces roller life, retention of roller bearing lubricant, but increases system vibration and roller shell wear. The lubricant can spray from the rollers, softening the belt rubber, and leading to belt splice or belt cover failure, which then needs to be replaced. Increasing the idler roller set spacing or pitch reduces the number of parts that can fail, however, it increases the contact pressure between the belt and rollers, therefore reaching a limit.

2017/045012

PCT/AU2016/000320

Accordingly, it has been very difficult to achieve a significant change in conveyor system length, capacity, and cost, using existing technology.

It is therefore an object ofthe present invention to provide a very long high capacity single flight conveyor belt system that ameliorates at least some of these aforementioned problems.

Disclosure of the Invention

Accordingly, the present invention is a conveyor belt system having a carry section and a return section, and a continuous belt. The system including a foundation formed from slip formed concrete, for at least for the carry section, that enables rapid lineal construction of the foundation in situ. The conveyor system also includes a plurality of discreet idler roller support frames for the continuous belt, and each idler roller support frame supports at least one idler roller. Each discreet idler support frame includes a pair of feet, and each foot is connectable to a support pad assembly by way of fastening means, and once attached, the idler support frame is placed onto the foundation, whereat the support pad is fastened to the foundation, and the rate at which each idler support frame is fastened onto the foundation matches the rate of deployment of the foundation.

Alternatively, if only the fasteners are placed first into the wet or uncured concrete, ready to accept the support frames after curing, the rate of fastener placement would match the foundation deployment.

Preferably, at least a portion of the support pad assembly, or fixing, is submerged into the concrete while the concrete is wet or uncured.

Alternatively, at least a portion of the support pad assembly or fixings is attachable to the concrete after the concrete has had time to partially or fully cure.

Preferably, the deployment of the slip formed foundation is at least 65 metres per hour.

2017/045012

PCT/AU2016/000320

Preferably, each support pad assembly is rectangular in shape, having an upper face and a lower face, and when the support pad assembly is fastened to the foot, the upper face is in direct contact with the foot. The lower face, when the idler support frame is placed onto the concrete foundation, sits upon the surface of the concrete.

Preferably, the upper face includes a longitudinal slot that is adapted to receive at least one fastener that is used to connect the idler support frame to the support pad assembly, and the longitudinal slot enables the idler support frame to be slidable within the limits of the longitudinal slot so that it can be repositioned relative to the support pad assembly prior to the tighten ing of the at least one fastener.

Preferably, each foot includes at least one slot that is adapted to receive the fastener means, and the direction of the at least one slot is orthogonal to the longitudinal slot so that the position each foot of the idler support frame, relative to it respective support pad assembly, can be adjusted in two axis, thereby enabling the position of each idler support frame in the system to be precisely aligned.

Preferably, each support pad assembly includes at least one anchor that extends substantially vertically downwardly from the lower face, and the at least one anchor is the portion of the support pad assembly that is submerged into the wet or uncured concrete.

Preferably, the length of the anchor that extends downwardly is substantially the same as the thickness of the concrete foundati on.

Optionally, the length of the anchor is adjustable so that the position of lower face of the support pad assembly, relative to the concrete surface, can be adjusted vertically to maintain the correct level of the assembly in the wet concrete or uncured concrete.

In another preferred aspect of the invention, the diameter of each idler roller is at least 280mm in diameter. The relati vely large diameter of each idler roller reduces the belt indentation loss attributed to each roller as the belt passes over it, thereby

2017/045012

PCT/AU2016/000320 significantly reducing power loss in the system. The larger diameter also causes the idler roller to rotate at a lower RPM for the same lineal belt speed, thereby creating a corresponding reduction in bearing drag loss for each idler. The force to rotate the bearing and its seal, at the roll circumference, is also reduced due to the larger roll radius. The combination of low indentation loss and reduced bearing and seal drag loss, allows the system to be driven at a comparatively faster belt speed for the same power consumption. The higher belt speed enables the belt width to be decreased for the same rate of payload carry, thereby making the belt cheaper and lighter, and it also enables the spacing between the idler support frames to be increased, thereby enabling the conveyor belt system to be constructed more quickly, efficiently, with reduced capital cost, and reduced maintenance cost.

In another embodiment, a variety of combinations of large diameter idler rollers that have a minimum diameter of 280mm and smaller conventional diameter idler rollers can be used together. For example, in a 3 roll carry set, the centre roll could be 320mm, and the outer wing or oblique angled idler rollers could be 178mm diameter. The return rolls could be 280mm plus or smaller conventional idler rollers.

Additionally, the idler roller’s lower RPM substantially reduces system vibration, noise, and roller bearing wear and tear, which reduces maintenance costs, and results in a lower environmental impact, greater reliability, and longer system up times. Another benefit is the reduction in the risk of bearing lubricant loss due to high roll RPM. This leads to early bearing failure. Also, lubricant from the bearing sprayed on the belt softens the rubber, causing softening and premature failure. The larger roll allows much higher belt speeds for the same or lower RPMs. Another benefit is the improved bearing life. Bearing life is inversely proportional to the RPM and the cubic power of the load, and load is proportional to the belt speed. If the idler pitch, i.e. the space between idler rollers, is increased in proportion to the belt speed, the bearing load, and life are unchanged. Then if say 178mm diameter rolls at 4m/s are compared to 320mm rolls at 6m/s, the rotational speed is reduced and the bearing life improves by 20%.

2017/045012

PCT/AU2016/000320

Additionally, the higher belt speed reduces the force to move the conveyor which causes a corresponding reduction in power required to drive the system, which thereby reduces the tension differential across the drive pulley(s), otherwise known as the head tension minus take-up tension. The reduced tension differential thereby permits the take-up tension at the drive pulley(s) to be increased, while maintaining a relatively low head tension, which also enables the spacing between idler support frames to be increased, and a reduced number of drive pulleys, and higher belt speeds, while avoiding payload lift-off, and enabling the head tension to be comparatively low.

The increased spacing between idler roller frames enables the conveyor belt system to be constructed with at least 50% less idler rollers.

Furthermore, the reduced tensions and belt strengths enable the conveyor system to be constructed using pulleys having a smaller diameter, thereby reducing their capital cost, system running costs, and transportation and handling requirements onsite for the pulleys during the construction phase of the conveyor belt system.

In a further aspect of the invention, the system includes a turnover that repositions the return path of the belt to a position above and overlaying the delivery path, so that the return path acts substantially as a roof over the delivery path, thereby substantially protecting the payload from the elements, and also eliminating the requirement for the construction of a roof. This significantly reduces the construction time and material cost for the conveyor belt system, and also enables the conveyer system to be constructed with a lower profile, which reduces the conveyor belt system’s susceptibility to the undesirable effects of wind loads.

Additionally, the turnover also flips the load carrying surface of the belt so that it remains upwardly facing on the return path so that the return idlers are always presented with the comparatively clean, “low energy loss”, underside of the belt, thereby reducing the power requirements to drive the conveyor system, and reduces roller failures and clean up on the return path.

2017/045012

PCT/AU2016/000320

Furthermore, the lower power requirements for the system means that the power of each drive motor can be reduced and/or the number of drive motors required to drive the system can be reduced, thereby resulting in lower capital expenditure and lower energy consumption costs to run the conveyor belt system.

In another aspect, the present invention provides a conveyor system including a foundation system, a flexible load carrying belt, and a plurality of roller clusters, each roller cluster including a roller mount and at least one roller rotatably secured thereto, the roller clusters solely provided structural support by the foundation system, where in the foundation system is suitable for stabilising against movement between at least two adjacent roller clusters due to at least one force.

In another aspect, the present invention provides a conveyor support system for supporting a flexible load carrying continuous belt in a conveyor system, the conveyor support system including a foundation system having a mass, at least one roller cluster having a position in the conveyor support system, each roller cluster including at least one roller mount and at least one roller having a diameter and rotatably secured to the mount, each roller mount having a height, wherein each roller cluster is solely provided structural support by the foundation system, and wherein the diameter of each roller, the height of each mount, and the mass of the foundation system are suitable for stabilising each roller cluster against movement from its position during operation due to at least one force.

In yet another aspect, the present invention provides a conveyor foundation system for a conveyor system, the conveyor system including a flexible load carrying belt for carrying material, and at least one roller cluster having a position in the conveyor system, each roller cluster including at least one roller mount and at least one roller having a diameter and rotatably secured to the mount, each roller cluster solely provided structural support by the foundation, the foundation having a mass and dimension suitable to stabilize the at least one roller cluster against movement from its position in the conveyor system due to at least one force.

2017/045012

PCT/AU2016/000320

Preferably, the foundation system stabilizes against: movement between roller clusters and the foundation system; and/or movement of the foundation system; movement of the roller clusters in other direction; and/or movement of the conveyor system.

Preferably, the foundation system includes at least one body.

Preferably, the at least one body extends to support at least two roller clusters. In embodiments including two or more bodies, the bodies may abut each other, may be separate from each other by a short distance so as to include an expansion material there between, or may be separated from each other by a distance up to a majority of a distance separating adjacent roller clusters.

Preferably, the at least one body is integrally formed.

Optionally, the at least one body includes a slab formed from concrete.

In yet a further optional embodiment, the foundation system is narrower than each roller cluster mount in the carry section.

In another embodiment, the foundation system is narrower than each roller cluster mount in the return section.

In an embodiment, each roller cluster has a height defined from the top-most part of the top-most at least one roller to the bottom of the respective mount, wherein the mount secured to the foundation system has a securing strength, wherein the foundation system has a mass, and wherein the height, the securing strength and the mass are chosen such that each roller cluster is sufficiently opposed to the force in at least one direction so as to resist movement between the respective mount and the foundation system.

2017/045012

PCT/AU2016/000320

In another embodiment, the carry section extends side-by-side the return section.

In a further embodiment, the carry section extends above or below the return section.

In yet another embodiment, the mount of each return section roller cluster forms a common mount with a respective mount of a carry section roller cluster.

In yet a further embodiment, the conveyor system includes fewer return section roller clusters than carry section roller clusters.

Optionally, the conveyor system includes approximately one third as many return section roller clusters as carry section roller clusters.

In yet another embodiment, each carry section roller cluster comprises a roller cluster including a plurality of rollers sufficient to provide a required cross-sectional trough shape to the continuous belt.

In yet a further embodiment, each return section roller cluster comprises a roller cluster including a plurality of rollers sufficient to provide a required cross-sectional trough shape to the continuous belt.

In another optional embodiment, the conveyor system is at least suitable for transporting bulk material from a mining process or other industries that move bulk solids.

In another aspect, the present invention provides a conveyor system including a plurality of roller clusters supported on a foundation system, each roller cluster including, a plurality of rollers sufficient to provide a required cross-sectional trough shape to a continuous belt when in contact with the roller cluster, and a plurality of roller mounts, wherein each roller in the roller cluster is rotatably and removably

WO 2017/045012

PCT/AU2016/000320 secured to one of the plurality of roller mounts. The longitudinal axis of at least one roller in the roller cluster is spatially offset with respect to the longitudinal axis of at least one other roller in the roller cluster along the path defined by the direction of travel of the continuous belt, thereby forming at least two offset roller groups, wherein each roller group is located on a separate mount.

In another aspect, the present invention provides a roller cluster including, a plurality of rollers sufficient to provide a required cross-sectional trough shape to a continuous belt when in contact with the roller cluster, when the roller cluster is in a conveyor system, and a plurality of roller mounts, wherein each roller in the roller cluster is rotatably and removably secured to one of the plurality of roller mounts, wherein the longitudinal axis of at least one roller in the roller cluster is spatially offset with respect to the longitudinal axis of at least one other roller in the roller cluster along the path defined by the direction of travel of the continuous belt, thereby forming at least two offset roller groups, wherein each roller group is located on a separate mount.

In one embodiment, each roller group and its frame are configured to allow access to each roller in the roller group from a side of the conveyor system parallel with the direction of travel of the continuous belt.

In another embodiment, each roller group and its frame are configured to allow access to each roller by a roller installation and removal device from a direction substantially coincident with the longitudinal axis of the roller.

In yet another embodiment, a majority of at least one end of each roller is open to the side of the conveyor system parallel with the direction of travel of the continuous belt.

2017/045012

PCT/AU2016/000320

In a further embodiment, the roller installation and removal device is separate from the conveyor system, and the roller installation and removal device is operable to remove a roller from its mount.

In yet a further embodiment, the roller installation and removal device includes a fork with at least two tines.

In an optional embodiment, the fork and each tine are configured to engage with the roller such that substantially vertical movement ofthe roller installation and removal device causes substantially vertical movement of the roller.

In another optional embodiment, each tine includes an angle member along its length, and wherein the angle member is inwardly facing with respect to the fork.

In yet another optional embodiment, each roller and its mount are configured to allow each tine to move from the side of the conveyor system parallel with the direction of travel of the continuous belt and engage with respective parts of a side of the roller.

In a further optional embodiment, each mount includes at least two struts, each strut including a cradle, wherein each pair of cradles is configured to rotatably and removably secure one roller, and wherein each strut has a width narrower than the diameter of the roller.

In yet a further optional embodiment, the roller includes an axle including axle protrusions extending from each end of the roller, and wherein each protrusion is configured to sit in a respective cradle.

In yet another embodiment, one axle can be extended a suitable distance for lifting with a matching female part that is carried on the lifting arm.

2017/045012

PCT/AU2016/000320

In yet another embodiment, the li ftin g devi ce can use a magnet to attach itself to the roll.

In an embodiment, the axle is either a live or dead shaft axle.

In another embodiment, the spatial offset between the roller groups is a distance sufficient to allow the operation of the roller installation and removal device on a selected roller in a selected roller group without interference from an adjacent spatially offset roller group.

In a further embodiment, each roller group and its frame are configured to allow access to each roller in the roller group from a side of the roller cluster parallel with the direction of travel of the continuous belt.

In yet another embodiment, each roller group and its frame are configured to allow access to each roller by a roller installation and removal device from a direction substantially coincident with the longitudinal axis of the roller.

In yet a further embodiment, a majority of at least one end of each roller is open to the side of its roller cluster parallel with the direction of travel of the continuous belt.

In an optional embodiment, the roller installation and removal device is separate from the roller cluster, and the roller installation and removal device is operable to remove a roller from its mount.

In yet another embodiment, each roller and its mount are configured to allow each time to move from the side of the roller cluster parallel with the direction of travel of the continuous belt and engage with respecti ve parts of a side of the roller.

2017/045012

PCT/AU2016/000320

In another aspect, the present invention is a stacked turnover for use in a conveyor belt system having a continuous belt that defines a carry belt when the belt is travelling in the payload carrying direction, and a return belt, when the belt is returning to the loading point of the conveyor belt system. The stacked turnover includes a support framework as follows:

The Lower Framework Portion includes:

- at least one lower return path idler roller, and

- a lower retention roller, and

- a first quarter helix twist, and

- a lower vertical turnover pulley, and

- a second quarter helix twist, and

- a lower horizontal turnover pulley.

The Bridging Portion includes:

- a vertical return belt portion that bridges the lower and upper portions.

The Upper Framework Portion includes:

- an upper horizontal turnover pulley, and

- a third quarter helix twist, and

- an upper vertical pulley, and

- a fourth quarter helix twist, and

- an upper retention roller, and

- a plurality of upper return path idler rollers.

Preferably, the upper portion of the turnover is stacked vertically upon the lower portion.

In a preferred form of the invention, the return belt is configured via a pulley to travel a distance along the same path, and in the opposite direction, below the level of the carry belt. The return belt is supported by the at least one lower return path idler roller while transiting the distance, and at the end of the distance, the return

2017/045012

PCT/AU2016/000320 belt enters the turnover, whereat it is configured to form the first quarter helix twist between the lower guide roller and the lower vertical turnover pulley. The lower vertical turnover pulley redirects the return belt substantially 90° so that it travels in a lower sideways direction to the path of the conveyor, and as the belt transits the lower sideways distance, it is configured to form the second quarter helix twist between the lower vertical turnover pulley and the lower horizontal turnover pulley. The lower horizontal turnover pulley redirects the return belt substantially 90° to travel a distance substantially vertically upwardly to the upper horizontal turnover pulley, which is located at an elevation above the level of the carry belt, and the upper horizontal turnover pulley redirects the return belt substantially 90° to travel back towards the conveyor belt system above the level of the carry belt, and as the belt transits the upper sideways distance, it is configured to form the third quarter helix twist between the upper horizontal turnover pulley and the vertical turnover pulley. The vertical turnover pulley redirects the belt 90° and configures the belt to form the fourth quarter helix twist between the upper vertical turnover pulley and the upper retention roller, so that the return belt can then travel back along the return path of the conveyor belt system in a location above the carry belt with the low energy side of the belt in contact with the plurality of return path idler rollers. By the time the return belt has completely transited the turnover, it has moved from a position where it is directly beneath the level of the carry belt, with the low energy side of the belt facing upwardly, to a position directly above the cany belt, with the low energy side of the belt facing downwardly, and in contact with the return path idler rollers.

Preferably opposite hand helix twists are used on each level of the turnover, and the opposite handedness of the helix twists balances the belt tension across the width of the belt, as the belt transits the stacked turnover.

Preferably the lower and upper portions of the turnover are vertically arranged and the support frame shares a common foundation.

Preferably the four quarter helix twists are short and thereby enable the stacked turnover to be compact.

2017/045012

PCT/AU2016/000320

The lower and upper horizontal turnover pulleys are adjustable and enable the tracking of the belt to be adjusted to provide proper alignment of the belt.

Preferably the pulleys used in the turnover have a wide face width and allow a large tracking range during the commissioning and operation ofthe conveyor belt system.

Preferably the turnover can be reconfigured to enable replacement belt to be pulled into the conveyor belt system, and/or the old belt to be removed.

Preferably the turnover can be reconfigured to enable the fitting of a single loop of belt that can be several kilometers long in a single operation.

The preceding makes it possible to construct a high capacity, very long, single flight, conveyor system that can be constructed relatively quickly, using fewer components, and the components required are generally available from normal component suppliers.

Brief Description of the Drawings

Tor a better understanding of the invention, to show how it may be performed, optional embodiments thereof will now be described by way of non-limiting examples only and with reference to the accompanying drawings in which:

figure 1 shows the prior art.

figure 2 is an isometric view of the present invention showing an idler roller cluster with the feet of each of the idler roller support frames attached to a support pad assembly.

figure 3 is an isometric view of the basic carry belt idler cluster structure of the present invention attached to a slip formed concrete foundation.

2017/045012

PCT/AU2016/000320

Figure 4 is an isometric view of both the carry belt and return belt structure of the present invention where the return belt is configured to overlay the carry belt, and thereby act as a roof for the carry belt.

Figure 5 is an end view of the structure and components of the present invention that is shown in Figure 4.

Figure 6 is an isometric view of the present invention showing an alternative preferred embodiment that shows an idler roller cluster on the carry belt connected to a pair of common support rails.

Figure 7 is a side elevation view of a part of a conveyor system, a conveyor support system and a conveyor foundation system in accordance with an embodiment of the present invention, showing five roller clusters supported along the foundation.

Figure 8 is a side elevation view of the return path of a conveyor system in accordance with the present invention, showing two return belt idler roller clusters, each supported on separate foundations.

Figure 9 is a perspective view of a conveyor system, a conveyor support system and a conveyor foundation system in accordance with an embodiment of the present invention, showing operators using roller installation and removal devices on rollers in roller cluster, and showing a carry and return section of the conveyor system. In this view, the carry belt and the return belts are arranged side by side, on separate foundations.

Figure 10 is a top plan view of the illustration in Figure 9.

Figure 11 is an end elevation view of a part of a conveyor system, its respective foundation and a roller installation and removal system in accordance with an embodiment of the present invention.

2017/045012

PCT/AU2016/000320

Figure 12 is a perspective view of a roller installation and removal device, optionally to be used for moving rollers in a generally horizontal configuration in a roller cluster in accordance with an embodiment of the present invention.

Figure 13 is a perspective view showing an alternative configuration of the roller installation and removal device showing an alternative roller installation and removal device, optionally for lifting rollers, which are positioned in roller clusters at an angle to the horizontal.

Figure 14 is a perspective view showing a detail of an operator operating a roller installation and removal device for substantially horizontally positioned rollers.

Figure 15 is a different perspective view with parts of the conveyor system removed for clarity.

Figure 16 is a top plan view of the illustration shown in Figure 15.

Figure 17 is another detailed view showing an operator using an optional roller installation and removal device configured to operate with rollers positioned at an angle to the horizontal in clusters in accordance with an embodiment of the present invention.

Figure 18 is a different perspective view to that shown in Figure 17 with parts of the conveyor system removed for clarity.

Figure 19 is an end elevation view of part of a roller cluster showing oblique rollers (otherwise known as wing idlers) connected to a mount of the roller cluster using a cantilever mounting.

Figure 20 is a perspective view of a roller cluster with the oblique rollers using the cantilever mounting.

2017/045012

PCT/AU2016/000320

Figure 21 shows an alternative embodiment of an idler roller lifting, carrying and positioning apparatus.

Figure 22 shows an isometric view of a preferred embodiment of the present invention including a belt turn over used at the delivery end of the conveyor belt system where the carry belt is “turned over” so that it becomes the return belt and positioned above the carry belt, to thereby act as a roof for the carry belt.

Figure 23 shows an isometric view of a preferred embodiment of the present invention including a belt turn over used at the loading end of the conveyor belt system where the return belt is “turned over” so that it becomes the carry belt and positioned below the return belt.

Figure 24 shows a side view of another preferred embodiment of the present invention including a belt turn over used at the unloading end of the conveyor belt system where the carry belt is “turned over” and positioned directly above the carry belt to become the return belt, and to act as a roof for the carry belt.

Figure 25 shows an isometric view of a simplified version of a belt turnover that is suitable for use at the end of the return path. This embodiment of the present invention is suitable for arrangements where the cany and return paths of the continuous belt are ananged in parallel, side by side.

Detailed Description of the Preferred Embodiments

Turning firstly to Figure 1, we can see an illustration of the prior art showing how the foundation is typically laid down as a series of discrete sleepers 360 upon which are bolted a pair of legs 340 which rise vertically and support a pair of longitudinal horizontal steel beams 370. Cross beams 350 complete the support structure for the conveyer belt. A plurality of carry idler roller support cross beams 380 support a plurality of comparatively small diameter idler rollers 314. Below the line of the carry rollers is a plurality of return belt idler rollers. For the purposes of this illustration, no roof is shown. It can be seen from this illustration that the

2017/045012

PCT/AU2016/000320 construction of a basic conveyor belt system uses a lot of steel, which increases cost, is heavy, and must be transported to the remote site of the construction camp and manipulated into position using the appropriate handling equipment.

The belt used in conveyor belt system is typically constructed with a high indentation energy loss, high wear resistant, side that carries the payload, and a low indentation energy loss side that engages with the pulleys and plurality of carry idler rollers. As the belt passes over each idler roller, the roller causes an indentation in the belt rubber. It takes energy to create this indentation, and the non-linear elasticity, or hysteresis, of the rubber, does not return all of this energy back to the system. The effect of this is termed indentation loss, and when multiplied over hundreds, or thousands of rollers, in a long path conveyor system, it adds up to one of the greatest sources of system power loss. In prior art systems, the carry idler rollers typically have a comparatively small diameter. Smaller diameter rollers suffer from higher indentation loss that higher diameter rollers thereby cumulatively creating higher power loss across the entire conveyor belt system. Further to this, because the carry idler rollers have a small diameter, the RPM at which they must rotate for any given belt speed is higher than it would be for a roller with greater diameter. Each roller is carried on the system via a set of bearings. As the roller turns, so too does its bearings and seals. The higher idler roller RPM on prior art conveyor system causes the roller bearing to rotate faster, leading to increased bearing drag and seal loss in each roller. When this is accumulated over hundreds, or thousands of rollers, the loss, otherwise known as roll drag loss, is another significant contributor to overall system power loss. Also the higher RPM components wear out faster, thereby requiring maintenance more often.

Also in conventional conveyor belt systems, the return path of the conveyor belt, otherwise known as the return belt, typically returns beneath the carry path of the belt, otherwise known as the carry belt. The return belt is typically rolled over a pulley at each end of the conveyor flight so that the high loss, high wear resistant, side of the belt is in direct contact with the return path idler rollers. This creates a number of significant problems. Firstly, the carry side of the belt is usually comparatively dirty, and over time this dirt builds up on the return path idler rollers,

2017/045012

PCT/AU2016/000320 thereby impacting their performance and efficiency, and reliability. Secondly the debris and dust can adversely impact the performance of the return path idler roller bearings, and require extensive clean up and occupational health and safety issues with slips and trips. Thirdly, because the return path idler rollers are in direct contact with the high loss side of the belt, it is a far less energy efficient arrangement. The effect of this is a system that has comparatively high system energy loss and less reliability, and system up time. This means that the belt runs at a slower speed for a given power supply. Therefore, in order for the system to provide the same material delivery rate, the belt needs to be wider.

For very long conveyor flights such as 15km to 35km in length, that are capable of providing a high delivery rate of material, the power required to drive the system is extremely high, thereby requiring large components to generate and handle that amount of power. This increase in component size can often exceed the standard components available in supplier catalogues, and therefore requires their special manufacture, delivery and handling, which adds significantly to the cost of the overall conveyor system. In addition, the use of non-standard parts may add substantially to the down time if a specially manufactured part is required urgently, and there is a delay in its special manufacture.

Furthermore, these long conveyor flights can span across extremely arduous terrain that may be extremely hot, or cold for example. During the construction phase of the conveyor system, it may require many thousands of people to encamp in this environment. Also because there is so much steel used in the construction of conventional long flight conveyor systems, the capital expense of the materials and components used in the system is significant to the viability of the project. Also the cost of the logistics in carrying all this material and components to the site is a significant cost imposition on the project.

Also the conventional practice of laying down a sequence of large pre-cast railway style concrete sleepers, or cast in-situ foundations, or bored piers/piles, to act as the system foundation, is comparatively slow. Also conveyor systems are exposed to the elements. Many require a roof to protect the payload from the elements. This

2017/045012

PCT/AU2016/000320 roof not only adds material cost to the cost of the project, but it also raises the profile of the system. This makes the system more susceptible to the deleterious effects of wind force on the structure. The comparatively light foundation may not be able to adequately resist the wind forces, and a portion of the system may slip out of alignment thereby further reducing the overall efficiency and reliability of the system. The structural components of the roof system often also restrict access for maintenance activities on the conveyor system.

Conventional conveyor systems are also very susceptible to vibration and noise, which may have an undesirable environmental impact, for example in quiet rural areas. The vibration may also be a source of system failure and unreliability.

Turning now to Figure 2, we see an isometric view of the carry portion of one form of the present invention. In this view we can see that instead of a massive metal frame structure to support the conveyor system, the present invention uses a simpler idler roller cluster 12 that are laid down in a sequence along the carry path of the conveyor system. Each roller cluster 12 comprises separate obliquely angled idler rollers 3 and a horizontal idler roller 5. Each of these rests on a simple frame that includes a pair of feet 7. Each foot 7 is fastenable to a support pad 9. In this form of the invention, the upper face of each support pad 9 includes a longitudinal foot slot 11. The longitudinal foot slot 11 is adapted to receive the foot 7 fastener means, and when the fasteners are loose, the foot 7 is able to slide within the confines of the foot slot 11 so that the position of the foot 7 can be moved with respect to the support pad 9. Optionally each foot 7 also includes an orthogonal foot slot 13 that is substantially orthogonal to longitudinal foot slot 11. The two slots combine to enable each foot 7 to be positioned relative to the support pad assembly 9 in two axes, as indicated by the X and Z axis depicted on the figure.

In this figure, we are also shown a plurality of support pad anchors 15 that are shown here in the form of rods that extend vertically down from the underside of each support pad 9.

2017/045012

PCT/AU2016/000320

Not shown in this illustration is the foundation that the conveyor system of the present invention is supported by. The foundation is a slip formed concrete slab. The foundation may be laid down in a long continuous strip, or a plurality of discreet strips. This is a highly efficient way of laying down the foundation and permits rapid constructi on of the foundation as the ground in front of the foundation can be continuously pre-prepared, and the foundation can continuously follow behind by continuously slipping the concrete foundation form forward as the concrete is continuously poured. This produces a high quality, constant thickness, concrete foundation at a rapid lineal rate. While the concrete is wet, each pre-prepared idler roller frame in each roller cluster 12 can be placed upon the wet concrete. Each of the support pad anchors 15 is submerged in the wet concrete, and the lower face of the support pad 9 sits upon the concrete. The slip former may be GPS controlled and working to a 3D alignment fed into its controller and the ground surface. An alternative to the slip former is a 3D concrete printer that lays down a pattern of concrete via a nozzle controlled by a computer, logic controller and associated computer software. It should be noted that when an accurate positioning technology, such as a GPS controlled system is used, then the longitudinal and orthogonal position adjustment slots in the feet may be reduced, or completely removed.

A variety of suitable concretes or geopolymers could be used. In addition, suitable reinforcement could be incorporated into the concrete or geopolymer. Examples of this include steel, stainless steel, polymer and/or carbon fibres, or similar. This allows the concrete, concrete fibre mix or geopolymer mix to be fed into the slip former without the need for further reinforcement. Alternatively, a steel or polymer mesh could be used, or a combination of both a mesh and the steel, stainless steel, polymer and/or carbon fibres.

In a further embodiment, the slip former can be driven over pre-placed expansion joints. The expansion joints can be made from a suitable timber, steel or synthetic material.

2017/045012

PCT/AU2016/000320

In a preferred form of the invention, the length of each support pad anchor 15 closely matches the thickness of the concrete foundation, so that no portion of the support pad assembly 9 is submerged into the wet concrete.

Optionally, the length of each support pad assembly anchor 15 is adjustable, thereby allowing the means to fine tune the vertical position of each foot 7 relative to the slip fonned concrete foundation, as depicted by the Y axis in the figure. Also optionally, the bottom of the support pad can include an adjustable item to set the height and prevent corrosion.

Optionally other shapes of anchor could be used. Each mount in the roller cluster can be fixed to the slip fonned foundation by use of pins, anchor screws, auger screws, U or L shaped anchors, hooks, all thread studs, drop in anchors, Dynasets™ Dynabolts™, expansion anchors, Chemsets™, reinforcing bar, bolts, screws, rivets, wedges, adhesive materials, either with steel fixings, glued into a drilled hole or steel plate glued to the concrete, nail gun, wet-set anchors, clamps, tensioned steel band(s) or cables, grouted pockets, direct welding to an embedded plate, or other securing means. These fixings can be applied before or after the concrete has cured. The items can be dropped, vibrated, hammered, pushed or screwed into the wet or uncured concrete or they can be placed prior to the arrival of the slip former.

Post tensioned steel bands or cables, can be laid on the ground, in front of the slip forming machine. They would then be tensioned after the concrete has cured and the steel items are in place. Small dowels can be drilled, or nail gun or similar can be used, to fix the steel items from moving sideways. Another option is to place timber, styrene foam, or similar blockout forms at locations where the main fixings would be located. The concrete foundation slip former then drives over these items. They are subsequently removed after the concrete has cured to allow one of the various forms of fixings to be used.

The concrete may be wet, semi-cured, or fully cured. If the fixings are placed in the wet or uncured concrete, a small pencil vibrator or similar can be used to either insert the fixing into the concrete, or have the concrete form around the fixing after

2017/045012

PCT/AU2016/000320 insertion. Temporary formwork can be used if required to hold up the concrete during the fixing insertion process. A short length of formwork can be used to both vibrate and maintain the concrete edge structure.

It must also be noted that the slip formed concrete foundation system, and the variations of fixings, may be used in conjunction with conventional conveyor belt systems, and not just conveyor systems of the type that form aspects of the present invention. Equally, conventional idler sets with <220mm diameter rolls can be combined with the slip formed foundation and carry side under the return side configuration.

There are several significant advantages of this mode of construction over that of the prior art. Firstly, the amount of structure required to construct the conveyor system is significantly reduced. The individual idler frames 1 that make up each roller cluster 12 can be pre-prepared, and the rate at which they are positioned in the slip formed concrete foundation can match the rate of construction of the foundation. The longitudinal foot slots 11 in the feet 7 and the support pad assembly 9 enables each idler support frame to be positioned accurately on the foundation. The direct connection to the relatively high weight continuous concrete foundation gives the conveyor system much greater stability.

Turning to Figure 3, we are shown an isometric view of a basic form of the invention showing further detail of how idler roller frames 1 of a roller cluster 12 are positioned on the slip formed concrete foundation 110. Note that in this view, the support pad is not shown, and each foot 7 is directly fastened to the slip formed concrete foundation 110. In this embodiment, there are separate idler roller frames 1 that support a pair of oblique idler rollers 3, and a single horizontal idler roller 5. Each idler roller cluster 12 is spaced apart along the length of the conveyor flight. These frames can be pre-assembled and ready to deploy in the wet concrete of the slip formed concrete foundation 110. This is highly efficient and enables the deployment of the idler roller clusters 12 to match the rate of construction of the concrete foundation. Also because of the low energy loss and higher belt speed features of the invention, then the spacing between idler roller clusters 12 can be

2017/045012

PCT/AU2016/000320 increased, thereby reducing the number of roller clusters 12 required to construct the conveyor belt, thereby reducing material, construction, logistical and maintenance costs.

Turning to Figure 4, we are shown a preferred form of the present invention where the return belt 23 has been configured to run above the carry belt 21. In this configuration, the return belt acts as a roof to the carry belt 21 and acts as a roof over the payload 25, thereby eliminating the need for a separate roof structure. This significantly reduces the material and time cost that would otherwise be attributable to the construction of the roof. It also provides the conveyor belt system with a lower profile that makes it less susceptible to the effects of wind loads.

In this form of the invention, the return belt idler roller support frame 17 is also anchored to the concrete foundation 110 in the same way as the carry belt idler roller support frames 1 in each roller cluster 12 are. In some circumstances, due to the height of the return belt idler roller support frame, it may be required to brace the return belt idler roller support frame 17 with a return belt idler roller support frame bracing member 27.

In a preferred form of the invention, a “turn over” (see Figures 22 through to 25) is used to flip the belt so that the “low energy loss” underside of the belt is always presented to the return belt idler rollers 19.

Figure 5 shows an illustration of the end view of preferred embodiment in Figure 4.

Turning to Figure 6, we are shown an alternative preferred embodiment of the present invention where the frames that support the idler roller assemblies in a typical roller cluster 12 share a common support rail 29 instead of individual support pads. It can be seen that the feet 7 for the rearward idler roller support frame 1 are arranged to align with the feet 7 of the forward idler roller support frame 1. This allows a construction crew to simply install a single pair of parallel rails at appropriate intervals along the length of the slip formed cement foundation. Alternatively, a crew can pre-assemble appropriate idler roller clusters 12 and mount

2017/045012

PCT/AU2016/000320 them to the common support rails 29, and then the assembly can then be attached to the concrete foundation.

The relatively larger surface area of the common support rails 29 minimises the problem of the support pad assemblies 9 (shown in Figure 2) from sinking into the wet concrete foundation. Each common support rail 29 has a continuous longitudinal slot 11 in its upwardly facing side that enables each individual idler roller support frame 1 to be positioned on the rail, as a pair, to form an idler cluster 12, and also positioned relative to one another. The rear idler roller support frame cross beam 33 extends substantially laterally outwardly, compared to the common support rails 29, on each side, to support the frame that carries the oblique idler roller 3. The oblique idler rollers 3 (one on each side) acts upon the side portions of the carry belt 21 so that the carry belt 21 forms a U shape with a substantially flat bottom portion as shown. The payload 25 is carried within the U shape. This minimises the capital cost of material and the weight of the material that needs to be transported to the construction site because only the oblique idler roller support frame requires the laterally extended crossbeam 33. The rigidity of the rear idler roller support frame is enhanced by the inclusion the oblique roller support frame angular brace member 35.

Turning now to Figure 7 where we are shown an extended side view of the embodiment shown in the previous Figures 2 through 6. The conveyor system 10 is shown with five roller clusters 12. Each roller cluster 12 is secured onto the foundation body 24 of the slip formed concrete foundation 110. In this view, it can be seen that the slip formed concrete foundation 110 is a discreet slab that extends to support five of the roller clusters 12 in the conveyor system 10. In a preferred embodiment, the slip formed concrete foundation 110 extends as a continuous slab to support all roller clusters 12 in the conveyor system 10. In an alternative embodiment, if there were ten roller clusters 12 on, for example, the carry section of the conveyor system 10, then the slip fonned concrete foundation 110 may be segmented, and therefore poured in discreet sections, with each section supporting a plurality of roller clusters. Each foundation segment may be joined to its adjacent segments in the conveyor belt system 10 via a suitable expandable joint. This allows

2017/045012

PCT/AU2016/000320 the concrete foundation 110 to better resist natural movements in the ground upon which it stands.

Turning to Figure 8, we are shown a side view of an alternative embodiment of the foundation system for use with the return flight of the conveyor system 10. In this form of the invention, the return flight is positioned adjacent to the carry flight in a parallel path (see Figure 9). The return path idler roller 19 is supported on a discreet foundation body 34.

Each of the return path foundation bodies 34 each must be adequately heavy so as to resist movement of the respective return path idler roller 19. Further, the roller mounts for the return path oblique rollers 19 have been selected to be relatively short, which reduces the overturning moment on each return path idler roller assembly 19 caused by movement of the return belt 23 during operation of the conveyor system 10, and the force and overturning moment induced from wind, earth tremor and other sources of movement.

Now turning to Figure 9, we are shown an embodiment of the aspects of the present invention, wherein the rollers are accessible from a side ofthe conveyor system 10 due to there being no requirement of a support structure or support beam system or stringers running along the sides of the conveyor belt to support the roller clusters. Operators 38 are operating roller installation and removal devices 36 to remove rollers for replacement or maintenance. An additional advantage of not requiring a support structure is that operators 38 can easily access the rollers 3 and 5 without having to remove the support structure, or move, slide, or rotate the roller mounts to do so.

Also shown is the conveyor system 10 as having a carry belt 21 for carrying bulk material from one end of the conveyor system to the other end of the conveyor system, and a return belt 23 for returning the belt 21 side-by-side. Arrows 26 show the respective direction of travel of both the carry and return belts. In this embodiment the carry section has a separate foundation that comprises a discreet number if individual foundation members 34 that are spaced apart from one another

2017/045012

PCT/AU2016/000320 and arranged to run in parallel to the foundation 110 for the carry belt. In this view we are shown an illustration of the slip formed concrete foundation 110 supporting five roller clusters 12 for the carry belt 21, whereas the return belt 23 has only two pair of return belt idler rollers 19 over the same distance, and each pair of return path idler rollers 19 have one discreet foundation body 34. The return path idler rollers 19 are likely to be subjected to less force, as the return belt 23 does not carry any payload 25, consequently the forces when the belt moves are significantly reduced. This, in turn, means that the foundation 34 for each roller cluster for the return belt 23 does not need to be as large, or as heavy, as the slip formed concrete foundation 110 for the carry belt. In alternative embodiment conveyor systems, both the carry and return path sections are carry sections, wherein the return section also carries payload. In such cases, a second parallel slip formed concrete foundation may be run in parallel to the first, or both paths can be carried on a single, wider, slip formed concrete foundation.

We are shown in Figure 10 a top plan view of the embodiment of the present invention that was shown in Figure 9. It can be more clearly seen in Figure 10 that the foundation bodies 34 for the return belt 23 of the conveyor system 10 are substantially smaller than the slip formed concrete foundation 110 for the carry belt 21 of the conveyor system 10.

Now turning to Figure 11 where we are shown an embodiment of the conveyor system 10 with separate foundation systems of the carry belt 21 section and the return belt 23 section, arranged side by side. The width of the slip formed concrete foundation 110 is shown as being substantially narrower than the width of the frame or mount in the roller cluster 12. This is possible because the oblique rollers 3 in the roller cluster 12 are on a common frame or mount, which is centered on the slip formed concrete foundation 110, and the mount cantilevers over the edge of the foundation.

In this embodiment, the wider foundation body 34 on the return belt 23 section provides the adequate resistance to movement and resistance against the forces produced when the belt is moving during operation of the conveyor system 10 or

2017/045012

PCT/AU2016/000320 wind, earthquake, etc. The resistance provided by the foundation bodies 34 and the slip formed concrete foundation 110 enables the conveyor system 10 to be built without use of table like support structures, which in turn enables ready access by an operator 38 using a roller installation and removal device 36 for maintenance of the rollers of the conveyor system 10.

Turning now to Figure 12, where we are shown an embodiment of a roller installation and removal device 36, which is configured for installation and removal of substantially horizontally positioned rollers 5. The device includes a body 42 with a horizontal fork 44, wherein the body and fork are configured so as to be at least partially counterbalanced when carrying a roller within the horizontal fork 44. The horizontal fork 44 includes two horizontal fork tines 46 and the body has handles 48 the horizontal fork tines 44 are each configured to have an inwardly facing angle for engaging with a side of a horizontal roller 5 such that, when inserted from an end of the roller, each tine snuggly engages a respective side of the horizontal roller 5.

When the horizontal roller 5 is snuggly engaged by the roller installation and removal device 36, the horizontal roller 5 can be lifted by the roller installation and removal device 36. In optional embodiments, the roller installation and removal device 36 can include an extra cantilever strut, that can be used as a lever to raise one end of the axle of the horizontal idler roller 5, first. In other optional embodiments, fixings, magnets or other means may be used to hold the horizontal roller 5 in place on the roller installation and removal device 36. Further alternatively, if the shaft of the roller is hollow, the lifting device 36 can be fitted with a protrusion that inserts into the shaft’s hollow end and is held in place by fixings, magnets or other means to hold the roller in place during installation and removal.

The roller installation and removal device 36 includes a top strut 50 and a bottom strut 52 onto which is fixed the fork 44. At a distal end of the top strut 50 there is fixed a cable 56 which extends to a spring load balancer 54, the spring load balancer 54 is then fixed to a crane or other such device for providing an appropriate

2017/045012

PCT/AU2016/000320 framework for the roller installation and removal device 36. Alternatively, a chain hoist or winch may be used with the device 36, for handling the horizontal rollers 5.

When an operator operates the roller installation and removal device 36, the spring load balancer 54 assists with lifting a roller that has been engaged by the device, therefore allowing for significantly heavier rollers to be used in a conveyor system. The spring load balancer renders the roller as weightless to facilitate handling by an operator.

It will be appreciated that the roller installation and removal device 36 can operate with roller clusters 12 because the idler roller frames in each roller cluster 12 are offset, which thereby allow for side access to all of the rollers in each cluster.

Turning now to Figure 13, where we are shown alternative embodiment of an oblique roller installation and removal device 60, which can be used for oblique idler rollers 3. It will be appreciated that the oblique roller installation and removal device 60 could be a different device from the device 36 shown in Figure 12. Alternatively, the oblique roller installation and removal device 60 in Figure 13 could be the same device 36 as shown in Figure 12, where that device is configured with a hinged fork so as to be able to adjust the angle of the fork for the rollers positioned either horizontally or at an angle to the horizontal.

Similarly to the horizontal roller installation and removal device 36 shown in Figure 12, the oblique roller installation and removal device 60 in Figure 13 has a body 62 onto which is attached an oblique fork 64, the oblique fork 64 also having two tines 66 and two handles 68. The oblique roller installation and removal device 60 has a top strut 70 and a bottom strut 72, onto which is attached the oblique fork 64. At a distal end of the top strut 70 there is attached a cable 76 which then attaches to a spring load balancer 74 and then attaches to a crane or other such appropriate frame for operating the oblique roller installation and removal device 60.

Turning now to Figure 14, we are shown a more detailed view of operator 38 using a roller installation and removal device 36 to engage with a horizontally positioned

2017/045012

PCT/AU2016/000320 roller 5 on its respective mount 18. As can be seen in Figure 14, the configuration of the device 36 allows the forks to engage with sides of the roller 5 while the top strut 50 of the device 36 is positioned above the carry belt 21 and the payload 25 thereon. The operator 38 uses handles 48 to position the device 36 so as to engage with the horizontal roller 5 when the device is moved in from a side of the conveyor system 10 to engage with the horizontal roller 5. The operator can operate the device to lift the roller out of its mount 18 using lifting force provided by the spring load balancer 54.

Turning to Figure 15 where we are shown a similar view to that shown in Figure 14, with the carry belt 21 removed for clearer visualization of the device 36 engaging with the horizontal roller 5. As can be seen, each tine 46 snuggly engages with a side of the horizontal roller 5 when the device 36 is moved in a direction from the side of the conveyor system 10 to engage with the horizontal roller 5. When the operator 38 engages the horizontal roller 5 with the device 36, the operator can then operate the spring load balancer 54 to lift the roller vertically.

In Figure 16 we are shown the view depicted in Figures 14 and 15 as a top plan view, also showing some internal features of a roller cluster 12 shown in broken lines, including oblique roller axles 30A, 30A prime and horizontal roller axle 30B.

Figure 17 is a perspective view showing detail of the operator 38 operating a roller installation and removal device 60 configured for engaging with oblique rollers 3. Figure 17 shows one of the two tines 66 in the device 60 engaging with a side of oblique roller 3 secured to its mount. It will be appreciated that roller 3 can be accessed from the opposite side of the belt from the side of the conveyor system (this side facing inward to the space between the carry and return sections of the conveyor system).

Figure 18 is another view of that shown in Figure 17 with the carry belt 21 removed for clearer visualization of the device 60 engaging with oblique roller 3. The oblique roller 3 on the opposite side can be removed with the same device 60 by positioning the device on the other side of the carry belt 21 of the conveyor system.

2017/045012

PCT/AU2016/000320

Figure 19 shows an alternative embodiment of a mount for obli que rollers 3, wherein the oblique rollers 3 are cantilevered. The oblique rollers 3 are mounted onto cantilevered oblique roller support 108 via oblique cantilevered mountings 109 and 109'. In this embodiment, cantilever oblique roller axles 106 and 106' are fixed to the cantilever mountings 109 and 109’ respectively. The oblique rollers 3 have a central bore which slides over the respective roller axles 106 and 106'. This configuration allows the rollers to be easily installed and removed by the oblique roller installation and removal device 60.

Figure 20 shows a perspective view of the cantilever wing roller system depicted in Figure 19 as part of a roller cluster 12. The horizontal roller 5 is spatially offset from the cantilevered oblique roller group.

Figure 21 shows an alternative embodiment of an idler roller lifting, carrying and positioning apparatus 80. The apparatus is fundamentally a wheeled lever, including a handle portion 82, and elongate body 84, and a pair of wheels 86, and a roller engaging portion 88. An operator is able to manually manipulate the apparatus 80 into position, relative to an idler roller. In this example, a horizontal idler roller 5 is depicted. It should be noted that the basic design could be easily varied so that the apparatus 80 could work easily with oblique rollers. The roller engaging portion 88 is inserted into the internal cavity of the roller shaft, over the extended shaft with a female part or over the roll with a fork that has at least two tines, or the device has a magnet, and the wheels 86 are then able to be used as a fulcrum to give the operator mechanical advantage in the lifting, carrying and positioning of rollers, as required.

In Figures 22 and 23 we are shown a turnover 100 in accordance with the present invention at each end of the conveyor belt system. The portion of the continuous belt is called the carry belt 21 and moves as shown in the direction indicated by the arrows.

As shown in Figure 22, at the end of the carry path, the carry belt 21 wraps around end pulley 105 and becomes return belt 23. Conveyor belts are typically constructed with a high wear and abrasion resistant side that carries to the payload, and a low

2017/045012

PCT/AU2016/000320 energy loss side that interacts with the conveyor belt system. A significant amount of energy loss is introduced into the system if the thick high wearing cover of the load carrying side of the belt is in contact with the return path idler rollers. As shown in Figure 22, as the carry belt 21 loops around the end pulley 105, the return belt 23 is positioned immediately below the carry belt with the load carrying side of the belt facing downwardly.

In many projects, it is desirable to construct a conveyor belt system where the return belt 23 is positioned above the carry belt 21 so that it can act as a roof. This eliminates the need to build and maintain a roof structure along the length of the conveyor belt system. This adds up to a substantial cost and time saving when constructing very long conveyor belt systems. It also allows the elevation and side profile of the conveyor belt system to be kept to a minimum, thereby limiting the effects of wind forces on the side of the conveyor belt systems that may move section of the conveyor belt system out of proper alignment. Not requiring a roof structure also considerably reduces the material cost and the equipment needed to construct and maintain the conveyor.

In this preferred embodiment, the turnover 100 places the return belt 23 above the carry belt 21. This moves the high load carry belt 21 to be nearest to the ground, and the light return belt 23 to be higher above the ground. The load on the return belt 23 is only the weight of the belt itself.

To reposition the return belt 23 so that it is properly oriented for energy efficiency and is elevated above the carry belt 21, a turnover 100 is constructed. The lower turnover return path idler roller 112 supports the return belt 23 as it runs off the end pulley 105. A lower turnover retention roller 111 prevents the return belt 7 from twisting prematurely. As the return belt 23 passes the lower retention roller 111, it is configured to commence forming the first quarter helix twist 113 between the lower retention roller 111 and the lower vertical turnover pulley 115. The lower vertical turnover pulley 115 changes the direction ofthe return belt 23 by 90° so that it moves sideways, relative to the carry belt 21. The return belt 23 is configured to form the second helix quarter twist 131 between the lower vertical turnover pulley

2017/045012

PCT/AU2016/000320

115 and the lower horizontal turnover pulley 117. The lower horizontal turnover pulley 117 redirects the return belt 23 upwardly to elevate the return belt portion 23 at 119. This elevates the return belt 23 to a position above the level of the carry belt 21. The return belt 23 then wraps around the upper horizontal turnover pulley 121, and this pulley redirects the path of the return belt 23 back towards the conveyor belt system. The third quarter helix 103 is formed between the upper horizontal turnover pulley 121 and the upper vertical turnover pulley 123 where the direction of the return belt 7 is again changed, roughly by 90°. A fourth and final quarter helix twist 125 is formed between the upper vertical turnover pulley 123 and the upper retention roller 127. The return belt 23 then travels back to the front of the conveyor along the return path that is elevated above the level of the carry belt 21. The return belt 23 is also orientated so that the higher energy efficient side, and cleaner side, of the belt is facing downwardly and in direct contact with the plurality of return path idler rollers, thereby maximising energy efficiency.

As shown in Figure 23, the turnover used at the loading end of the conveyor system is substantially the same, however the motion of the belt is reversed, as indicated by the arrows.

The inclusion of a turnover at each end of the system enables the construction of an extremely long, highly energy efficient, conveyor belt system with minimal support structure, material cost, reduced construction time, and longer up-time.

Other benefits of the preferred embodiment of the invention to hi ghly efficient, fast moving, ultra-long, conveyor belt systems include:

a) The turnover system is stackable, and also because each quarter helix twist takes a comparatively shorter distance, as the opposite handedness twists balance the tensions across the belt, this combines to significantly reduce the footprint of the turnover structure, and thereby reduces the amount of foundation required to support it. This reduces materials cost and construction cost, and also suits areas where there is restricted space in the vicinity of the ends of the conveyor belt system, for example at sea ports where other infrastructure may be located.

2017/045012

PCT/AU2016/000320

b) The comparatively short distances of each quarter helix reduces the requirement for additional helix support rollers to support the belt as it twists. This therefore reduces capital cost, maintenance, and improves reliability of the conveyor belt system.

c) By alternating the handedness of the multiple quarter helix twists, the tensile loads across the belt can be balanced out as it transits the turnover, thereby improving the life and reliability of the belt.

d) The upper and lower horizontal pulleys can be mounted onto a common adjustable support frame. This enables the tracking of the belt to be easily adjusted to ensure maximum efficiency.

e) Each pulley used in the turnover has a long face width, and this gives the turnover a large tracking range that the belt can operate in as it transits the turnover.

f) Support rollers are in place to allow the belt to be commissioned and detensioned for conveyor maintenance. As the belt is de-tensioned for maintenance, the belt tends to sag in the helix. Without the small support rolls, the belt may move off the face of the vertical and other support pulleys during commi ssioning or when the belt is de-tensioned. Also during commissioning, until the belt is tracked, by pulley and idler adjustment, the belt may move across the face of the pulleys, to a point where it may move off the pulley face. When a belt moves off the pulley face, catastrophic damage can occur.

g) The turnover can be reconfigured to allow a new belt to be pulled onto the conveyor belt system, and to remove a portion, or all of, the old belt from the system. This can be done for ultra-long conveyor systems having belts of several kilometres in length. Prior to the change out, individual reels of belting from the factory can be spliced together to form one continuous length. This is time consuming as each joint or splice between belt lengths on each reel, takes several hours to prepare and vulcanize. Once all the splices have been done, the conveyor system can then the

2017/045012

PCT/AU2016/000320 shut down, and taken out of service and the one complete belt length can be pulled onto the conveyor over several hours.

An alternative embodiment of the turnover used the present invention is shown in Figure 24. In Figure 24, we are shown the version of the alternative turnover 100 for use at the delivery end of the conveyor system. The carry belt 21 passes over the turnover end pulley 105 and becomes the return belt 23. The combination of the lower retention roller 111 and lower return path idler roller 112 combine to keep the return belt 23 in proper orientation so that it can form a first quarter helix twist 113 between the lower return path idler roller 112 and the lower vertical turnover pulley 115. The lower vertical turnover pulley 115 changes the direction of the belt by about 90° so that it is moved a short distance sideways, relative to the conveyor system. The distance is minimal to enable the return belt 23 to clear the carry belt 21. The return belt 23 is then passed around the lower oblique turnover pulley 141. The lower oblique turnover pulley 141 changes the direction and also upwardly angles the return belt 23 as shown at 145. At the end of the upwardly angled portion 145 of the turnover 100, the belt passes over the upper oblique turnover pulley 143. This changes the direction of the return belt 23 and the return belt 23 then passes to the upper vertical pulley 123 where the belt is again turned by about 90°. The upper helix quarter twist 125 is formed between the upper vertical turnover roller 123 and the upper retention roller 127 so that the belt side is properly orientated with respect to the return path idler rollers, and the return belt 23 is positioned above the carry belt 21 so that it may act as a roof for the carry belt 21. Preferably at least the lower and upper oblique turnover pulleys 141 and 143 respectively, are mounted on adjustable supports, and several small lower belt edge support rollers 147 are provided, that enable the belt tracking to be adjusted for maximum efficiency. The several small lower belt edge support rollers 147, also support the belt when the tension is released for maintenance activities. The turnover 100 is the essentially the same at the loading end of the conveyor belt system, however the direction that the belts travel through it are reversed.

The main advantage of this embodiment is the turnover is made comparatively compact and therefore requires a smaller foundation. The main disadvantage of this

2017/045012

PCT/AU2016/000320 alternative embodiment is that the turnover does not have the same balanced tensile load on the belt that the preferred embodiment has by using more helix quarter twists.

Figure 25 shows yet another embodiment of a suitable turnover for use on the conveyor belt system. This is a simple turn over that is very suitable for a side by side conveyor belt system. In this view, the return belt 23 engages with the first retention roller 150. Between the first retention roller 150 and the first vertical turnover pulley 152, the belt 21 is constrained to form a first quarter helix twist 158. The belt then proceeds around the first vertical turnover pulley 152, and moves a suitable distance in a substantially lateral direction 162 to the direction of the carry path. The belt then proceeds around the second vertical turnover pulley 154, and a second quarter helix twist 160 is formed in the belt between the second vertical turnover pulley 154 and the second retention roller 156. The direction of the second helix twist 160 is the reverse of the first helix twist 158. The belt now becomes the carry belt 21, and the belt is now ready to be loaded, and carries its load back along the laterally spaced paral lel path of the carry belt.

While the above description includes the preferred embodiments of the invention, it is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention.

It will be also understood that where the word “comprise”, and variations such as “comprises” and “comprising”, are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features. The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge.

2017/045012

PCT/AU2016/000320

Claims

Claims

1. A conveyor belt system having a carry section and a return section, and a continuous belt, said system including a foundation formed from slip formed concrete, for at least for the carry section, that enables rapid lineal construction of the foundation in situ, wherein the conveyor system also includes a plurality of discreet idler roller support frames for the continuous belt, and each idler roller support frame supports at least one idler roller, and wherein each discreet idler support frame includes a pair of feet, and each foot is connectable to a support pad assembly by way of fastening means, and once attached, the idler support frame is placed onto the foundation, whereat the support pad is fastened to the foundation, and the rate at which each idler support frame is fastened onto the foundation matches the rate of deployment of the foundation.
2. A conveyor belt system as defined in claim 1 wherein at least a portion of the support pad assembly is submerged into the concrete while the concrete is wet.
3. A conveyor belt system as defined in claim 1 wherein the rate of deployment of the slip formed foundation is at least 65 metres per hour.
4. A conveyor belt system as defined in claim 1 wherein each support pad assembly is rectangular in shape, having an upper face and a lower face, and when the support pad assembly is fastened to the foot, the upper face is in direct contact with the foot, and wherein the lower face, when the discreet idler support frame is placed onto the concrete foundation, sits upon the surface of the concrete.
5. A conveyor belt system as defined in claim 4 wherein the upper face includes a longitudinal slot that is adapted to receive at least one fastener that is used to connect the idler support frame to the support pad assembly, and the longitudinal slot enables the idler support frame to be slidable within the limits of the longitudinal slot so that it can be repositioned relative to the support pad assembly prior to the tightening of the at least one fastener.

2017/045012

PCT/AU2016/000320
6. A conveyor belt system as defined in claim 5 wherein each foot in the pair of feet includes at least one slot that is adapted to receive the fastener means, and the direction of the at least one slot is orthogonal to the longitudinal slot so that the position each foot of the idler support frame, relative to it respective support pad assembly, can be adjusted in two axis, thereby enabling the position of each idler support frame in the system to be precisely positioned.
7. A conveyor belt system as defined in claim 2 wherein each support pad assembly incudes at least one anchor that extends substantially vertically downwardly from the lower face, and the at least one anchor is the portion of the support pad assembly that is submerged into the wet concrete.
8. A conveyor belt system as defined in claim 7 wherein the length of the anchor that extends downwardly is substantially the same as the thickness of the concrete foundation.
9. A conveyor belt system as defined in claim 7 wherein the length of the anchor is adjustable so that the position of lower face of the support pad assembly, relative to the concrete surface, can be adjusted verti cally to maintain the correct level of the assembly in the wet concrete.
10. A conveyor belt system as defined in claim 1 wherein the diameter of each idler roller carried on its respective support frame is at least 280mm in diameter, and each idler roller with this minimum diameter or above reduces the belt indentation loss attributed to each idler roller as the belt passes over it, thereby significantly reducing power loss in the system, and wherein each idler roller rotates at a lower RPM for the same lineal belt speed, thereby creating a corresponding reduction in bearing drag loss for each idler roller, and also reduces the force required to rotate the bearing and its associated seal, at the idler roller circumference, thereby reducing the power requirement for the conveyor system, and enabling the conveyor system to operate at a higher lineal speed.
11. A conveyor belt system as defined in claim 10 wherein the belt width within the conveyor system is decreased for the same rate of payload carry, due to the increased lineal speed of the belt for the same power input, thereby making the belt

2017/045012

PCT/AU2016/000320 cheaper and lighter, and it also enabling the spacing between the discreet idler support frames to be increased, thereby enabling the conveyor belt system to be constructed more quickly and efficiently, with a significantly reduced capital cost, and significantly reduced construction and maintenance costs.
12. A conveyor belt system as defined in claim 10 wherein the idler roller’s lower RPM substantially reduces system vibration and noise, and roller bearing wear and tear, and therefore further reduces maintenance costs, and results in a lower environmental impact, greater reliability, and longer system up times.
13. A conveyor belt system as defined in claim 10 wherein the higher belt speed and the at least 280mm diameter idler rollers reduces the force required to move the conveyor, which thereby causes a corresponding reduction in power required to drive the system, and thereby reduces the tension differential across the drive pulley(s), and wherein the reduced tension differential thereby permits the take-up tension at the drive pulley(s) to be increased, while maintaining a relatively low head tension, which also enables the spacing between idler support frames to be increased, and a reduces the number of drive pulleys, while avoiding payload liftoff
14. A conveyor belt system as defined in claim 13 wherein the increased spacing between idler roller frames enables the conveyor belt system to be constructed with at least 50% less idler rollers.
15. A conveyor belt system as defined in claim 13 wherein the reduced belt tension and belt strength enable the conveyor system to be constructed using pulleys having a smaller diameter, thereby reducing their capital cost, system running costs, and transportation and handling requirements on-site for the pulleys during the construction phase of the conveyor belt system.
16. A conveyor belt system as defined in claim 1 including a turnover that repositions the return path of the belt to a position above and overlaying the delivery path, so that the return path acts substantially as a roof over the delivery path, thereby

2017/045012

PCT/AU2016/000320 substantially protecting the payload from the elements, and also eliminating the requirement for the construction of a roof.
17. A conveyor belt system as defined claim 16 wherein the positioning of the return path of the belt to a position above and overlaying the delivery path significantly reduces the construction time and material cost for the conveyor belt system, and also enables the conveyer system to be constructed with a lower profile, which thereby reduces the conveyor belt system’s susceptibility to the undesirable effects of wind loads.
18. A conveyor belt system as defined in 16 wherein the turnover also flips the load carrying surface of the belt so that it remains upwardly facing on the return path, so that the return path idler rollers are always presented with the comparatively clean, “low energy loss”, underside of the belt.
19. A conveyor belt system as defined in 18 wherein the power supply means required to drive the system is reduced, thereby lowering the capital expenditure and running costs of the system.
20. A conveyor belt system as defined in claim 1 wherein the slip formed concrete is laid down in sections, and each section provides the foundation to at least a pair of idler roller support frames.
21. A conveyor belt system as defined in claim 20 wherein adjacent sections either abut each other, or the adjacent sections are separated from each other by a short distance so as to form a gap.
22. A conveyor belt system as defined in claim 21 wherein when the gap is filled with an expansion material.
23. A conveyor belt system as defined in claim 1 wherein the slip formed concrete foundation is narrower than each idler roller frame mounted in the carry section.
24. A conveyor belt system as defined in claim 1 wherein foundation system for the return section is narrower than each return path idler roller frame.

2017/045012

PCT/AU2016/000320
25. A conveyor belt system as defined in claim 1 wherein the carry section extends side-by-side, and in parallel with the return section.
26. A conveyor belt system as defined in claim 18 wherein the frame of each return section idler roller is integrated with the frame of a respective frame of a carry section idler roller.
27. A conveyor belt system as defined in claim 26 wherein the conveyor system includes fewer return section idler roller support frames than carry section idler roller support frames.
28. A conveyor belt system as defined in claim 27 wherein the conveyor system includes approximately one third as many return section idler roller support frames as carry section idler roller support frames.
29. A conveyor belt system as defined in claim 1 wherein each the carry section comprises a plurality of idler roller support frames that are grouped into carry section idler roller clusters, and each cluster includes a plurality of rollers that are sufficient to provide a U-shaped cross-sectional shape to the continuous belt.
30. A conveyor belt system as defined in claim 29 wherein substantially each carry section idler roller cluster comprises a first idler roller support frame that carries a horizontal idler roller, and a nearby adjacent second idler roller support frame that carries a pair of obliquely aligned idler rollers.
31. A conveyor system as defined in claim 30 wherein the obliquely aligned pair of idler rollers act upon the edges of the continuous belt, to cause them to be turned obliquely upwardly, and the horizontal idler roller supports the middle section of the continuous belt, so that it remains substantially flat, so that the combination of the first and second idler roller support frames in the carry section idler roller cluster causes the continuous belt to form the U-shaped cross sectional shape.
32. A conveyor belt system as defined in claim 1 wherein each return section idler roller support frame comprises sufficient rollers to provide a required cross-sectional trough shape to the continuous belt.

2017/045012

PCT/AU2016/000320
33. A conveyor belt system as defined in claim 29 wherein each idler roller cluster is configured to allow access to each idler roller in the cluster from a side of the conveyor system.
34. A conveyor belt system as defined in claim 33 wherein each idler roller frame in each roller cluster is configured to allow access to each individual idler roller by a roller installation and removal device that is adapted to gain access to a specific roll from a direction substantially coincident with the longitudinal axis of the specific roller.
35. A conveyor belt system as defined in claim 34 wherein a majority of at least one end of each roller is open to the side of the conveyor system, parallel with the direction of tra vel of the continuous belt.
36. A conveyor belt system as defined in claim 35 wherein the roller installation and removal device is separate from the conveyor system, and the roller installation and removal device is operable to remove a roller from its respective roller mount within its idler roller frame.
37. A conveyor belt system as defined in claim 36 wherein the roller installation and removal device includes a fork with at least two tines, and each tine is configured to engage with the roller such that substantially vertical movement of the roller installation and removal device causes substantially vertical movement of the roller.
38. A conveyor belt system as defined in claim 37 wherein each idler roller and its respective mount is configured to enable each tine to move from a respective side of the roller parallel with the direction of travel of the continuous belt, and engage with respective parts of a respective side of the roller.
39. A turnover for use in a conveyor belt system as defined in claim 1, wherein the stacked turnover includes a support framework that provides a lower portion having:

- at least one lower return path idler roller, and

- a lower retention roller, and

2017/045012

PCT/AU2016/000320

- a first quarter helix twist, and

- a lower vertical turnover pulley, and

- a second quarter helix twist, and

- a lower horizontal turnover pulley; and

- a substantially vertical return belt portion that bridges the lower and upper portions; and an upper portion having:

- an upper horizontal turnover pulley, and

- a third quarter helix twist, and

- an upper vertical pulley, and

- a fourth quarter helix twist, and

- an upper retention roller, and

- a plurality of upper return path idler rollers, wherein the upper portion of the turnover is stacked vertically upon the lower portion, or is located on a parallel path alongside the lower portion.
40. A turnover as defied in claim 39 wherein the return belt is configured via a pulley to travel a distance along the same path, and in the opposite direction, below the level of the carry belt, wherein the return belt is supported by the at least one lower return path idler roller while transiting the distance, and at the end of the distance, the return belt enters the turnover whereat it is configured to form the first quarter helix twist between the lower guide roller and the lower vertical turnover pulley, and wherein the lower vertical turnover pulley redirects the return belt substantially 90° so that it travels in a lower sideways direction to the path of the conveyor, and as the belt transits the lower sideways distance, it is configured to form the second quarter helix twist between the lower vertical turnover pulley and the lower horizontal turnover pulley wherein the lower horizontal turnover pulley redirects the return belt substantially 90° to travel a distance substantially vertically upwardly to the upper horizontal turnover pulley which is located at an elevation above the level of the carry belt, and the upper horizontal turnover pulley redirects the return belt substantially 90° to travel back towards the conveyor belt system above the level of the carry belt, and as the belt transits the upper sideways distance,

2017/045012

PCT/AU2016/000320 it is configured to form the third quarter helix twist between the upper horizontal turnover pulley and the vertical turnover pulley, and the vertical turnover pulley redirects the belt 90° and configures the belt to form the fourth quarter helix twist between the upper vertical turnover pulley and the upper retention roller, so that the return belt can then travel back along the return path of the conveyor belt system in a location above the carry belt, or on a parallel path alongside the carry belt, with the low energy side of the belt in contact with the plurality of return path idler rollers, so that by the time the return belt has completely transited the turnover, it has moved from a position where it is directly beneath the level of the carry belt with the low energy side of the belt facing upwardly, to a position directly above, or alongside, the carry belt, with the low energy side of the belt facing downwardly and in contact with the return path idler rollers.
41. A turnover as defined in claim 39 wherein opposite hand helix twists are used on each level of the turnover, and the opposite handedness of the helix twists balances the belt tension as the belt transits the stacked turnover.
42. A turnover as defined in claim 39 wherein the lower and upper portions of the turnover are vertically arranged and support frame shares a common foundation.
43. A turnover as defined in claim 39 wherein the four quarter helix twists are short and thereby enable the stacked turnover to be compact.
44. A turnover as defined in claim 39 wherein the lower and upper horizontal turnover pulleys enable the tracking of the belt to be adjusted to provide proper alignment of the belt.
45. A turnover as defined in claim 44 wherein the pulleys used in the turnover are large and allow a large tracking range during the commissioning and operation of the conveyor belt system.
46. A turnover as defined in claim 39 wherein the turnover can be reconfigured to enable replacement belt to be pulled into the conveyor belt system, and old belt to be removed.

WO 2017/045012

PCT/AU2016/000320
47. A turnover as defined in claim 39 wherein the turnover can be reconfigured to enable the fitting of a single loop of belt that is at least 15,000 metres long in a single operation.

WO 2017/045012

PCT/AU2016/000320

1/24

314 ο

FCO

FIG. 1 PRIOR ART _vc

_Ο\6ΙΟ' ,0^1° \\O

111* ^CT'^iV201li'W0320

3/24 /

/

WO 2017/045012

PCT/AU2016/000320

4/24

FIG. 4

WO 2017/045012

PCT/AU2016/000320

5/24 <N

FIG. 5 _vc

₀l6l®' ,0037° \\O

WO 2017/045012

PCT/AU2016/000320

7/24

I I

WO 2017/045012

PCT/AU2016/000320

8/24

912*

WO 2017/045012

PCT/AU2016/000320

10/24

I !

II

FIG. 10

WO 2017/045012

PCT/AU2016/000320

11/24

FIG. 11

WO 2017/045012

PCT/AU2016/000320

12/24

FIG. 13

WO 2017/045012

PCT/AU2016/000320

13/24

110

WO 2017/045012

PCT/AU2016/000320

14/24 rru co co co

WO 2017/045012

PCT/AU2016/000320

15/24

FIG. 16

WO 2017/045012

PCT/AU2016/000320

16/24

LO

CN

WO 2017/045012

PCT/AU2016/000320

17/24

WO 2017/045012

PCT/AU2016/000320

18/24

FIG. 19 ^045(,,2 ^PCT/A_V

19/24

WO 2017/045012

PCT/AU2016/000320

20/24

CM

FIG. 21 ^,(o ²°1% °12

*012 ^pcj>

⁷AN

^6/Oo, °³2q

WO 2017/045012

PCT/AU2016/000320

23/24

LO

FIG. 24

CD

C\l

WO 2017/045012

PCT/AU2016/000320

24/24

152 /¹⁶² 154

FIG. 25 co

CM