The Roll Gen System is a self-contained mini power station that allows operators to run electrical monitoring systems and safety mechanisms. Being able to add a generator to a roller delivers the benefit of utilizing existing roller designs, while drawing power from the belt for a wide variety of electronic devices.
In the patent-pending design, a “drive dog” is attached to the end face of the roll that is resting on the generator, using magnets. The magnetic attachment ensures that electrical or mechanical overload does not force the roll to stop; instead the magnets will slip on the roll face.
The conveyor roll loads are carried by the large support shaft in the generator, which does not rotate and is rigidly mounted to the idler support structure. The generator forms a lightweight driven unit that does not affect the existing roll in any way, except to be rotationally engaged via the magnets, and so draw a small amount of mechanical power in order to generate the electrical energy.
On conveyors that already employ Martin Trac-Mount Idlers outside of a loading zone, installation is as easy as removing the wing slide on one end and replacing it with the Roll Generator slide, a 2-minute procedure. The generator can also be installed on its own mount or on other existing support structures, such as a belt tracker.
The reliable power supply allows users to equip their systems with devices such as weigh scales, proximity switches, moisture sensors, pressure switches, solenoids and relays, as well as timers, lights and even additional safety mechanisms. Wireless communication can be used to transmit directly to a central controller, giving operators a cost-effective way to access data that has not been readily available in the past.