Sensor systems and methods for detecting conveyor tension in a mining system

1. A conveyor system, comprising:

a sprocket;

a conveyor element of a conveyor, the conveyor element coupled to the sprocket to move around the sprocket;

a sensor array positioned adjacent to the sprocket, the sensor array configured to generate output signals indicating a position of the conveyor element, wherein the sensor array includes a plurality of binary proximity sensors and wherein each sensor of the plurality of binary proximity sensors corresponds to a different slack distance of the conveyor element;

a tensioning system; and

an electronic processor coupled to the sensor array and to the tensioning system, the electronic processor configured to

receive the output signals from the sensor array,

determine a tension state of the conveyor based on the output signals, and

control the tensioning system based on the tension state to change a tension of the conveyor element.

2. The conveyor system of claim 1 , wherein each binary proximity sensor is configured to provide a binary output signal of the output signals.

3. The conveyor system of claim 2 , wherein each binary output signal is either a first value that indicates that the conveyor element is detected or a second value that indicates that the conveyor element is not detected.

4. The conveyor system of claim 1 , wherein, to control the tensioning system based on the tension state, the electronic processor is configured to:

decrease the tension in the conveyor element when the tension state is over-tensioned, and

increase the tension in the conveyor element when the tension state is under-tensioned.

5. The conveyor system of claim 1 , further comprising:

a second sprocket;

a second conveyor element of the conveyor, the second conveyor element coupled to the second sprocket to move around the second sprocket;

a second sensor array positioned adjacent to the second sprocket, the second sensor array configured to generate second output signals indicating a second position of the second conveyor element; and

a second tensioning system;

wherein the electronic processor is coupled to the second sensor array and to the second tensioning system, the electronic processor further configured to

receive the second output signals from the second sensor array, and

determine the tension state of the conveyor based also on the second output signals.

6. The conveyor system of claim 5 , further comprising:

a plurality of flight bars, each flight bar connected between the conveyor element and the second conveyor element.

7. The conveyor system of claim 5 , further comprising:

a tension state map used by the electronic processor to determine the tension state,

wherein the tension state map associates potential map inputs from the sensor array and the second sensor array with a plurality of potential tension states of the conveyor,

wherein binary values of the output signals of the sensor array and the second output signals of the second sensor array together form a map input, and

wherein the tension state map associates the map input with the tension state.

8. A method for controlling tension in a conveyor element of a conveyor that moves around a sprocket, the method comprising:

generating output signals by a sensor array positioned adjacent to the sprocket, wherein the output signals from the sensor array are indicative of a position of the conveyor element;

receiving, at an electronic processor, the output signals from the sensor array, wherein the sensor array includes a plurality of binary proximity sensors and wherein each sensor of the plurality of binary proximity sensors corresponds to a different slack distance of the conveyor element;

determining, by the electronic processor, a tension state of the conveyor based on the output signals; and

controlling, by the electronic processor, a tensioning system based on the tension state to change a tension of the conveyor element.

9. The method of claim 8 , wherein each binary proximity sensor is configured to provide a binary output signal of the output signals, wherein each binary output signal is either a first value that indicates that the conveyor element is detected or a second value that indicates that the conveyor element is not detected.

10. The method of claim 8 , controlling the tensioning system based on the tension state includes:

decreasing the tension in the conveyor element when the tension state is over-tensioned, and

increasing the tension in the conveyor element when the tension state is under-tensioned.

11. The method of claim 8 , the method further comprising:

receiving further output signals from the sensor array,

determining an updated tension state of the conveyor based on the further output signals, wherein the updated tension state is an abnormal tension state that is distinct from an under-tensioned state, an over-tensioned state, and an adequately tensioned state, and

generating an alarm in response to determining that the updated tension state is the abnormal tension state.

12. The method of claim 8 , wherein the conveyor further includes a second conveyor element that moves around a second sprocket, the second conveyor element and the conveyor element connected by plurality of flight bars of the conveyor, the method further comprising:

generating second output signals by a second sensor array positioned adjacent to the second sprocket, wherein the second output signals from the second sensor array are indicative of a position of the second conveyor element; and

receiving, at the electronic processor, the second output signals from the second sensor array, and

wherein the determining of the tension state of the conveyor is based also on the second output signals.

13. The method of claim 12 , wherein, to determine the tension state, the electronic processor uses a tension state map that associates potential map inputs from the sensor array and the second sensor array with a plurality of potential tension states of the conveyor,

wherein binary values of the output signals of the sensor array and the second output signals of the second sensor array together form a map input, and

wherein the tension state map associates the map input with the tension state.

14. A controller for controlling tension in a conveyor element of a conveyor that moves around a sprocket, the controller including a non-transitory computer readable medium and an electronic processor, the controller comprising computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:

receive, at the electronic processor, output signals from a sensor array positioned adjacent to the sprocket, wherein the output signals from the sensor array are indicative of a position of the conveyor element, wherein the sensor array includes a plurality of binary proximity sensors and wherein each sensor of the plurality of binary proximity sensors corresponds to a different slack distance of the conveyor element;

determine, by the electronic processor, a tension state of the conveyor based on the output signals; and

control, by the electronic processor, a tensioning system based on the tension state to change a tension of the conveyor element.

15. The controller of claim 14 , wherein each binary proximity sensor is configured to provide a binary output signal of the output signals, wherein each binary output signal is either a first value that indicates that the conveyor element is detected or a second value that indicates that the conveyor element is not detected.

16. The controller of claim 14 , wherein, to control the tensioning system based on the tension state, the controller further includes computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:

decrease the tension in the conveyor element when the tension state is over-tensioned, and

increase the tension in the conveyor element when the tension state is under-tensioned.

17. The controller of claim 14 , wherein the conveyor further includes a second conveyor element that moves around a second sprocket, the second conveyor element and the conveyor element connected by plurality of flight bars of the conveyor, and the controller further includes computer executable instructions stored in the computer readable medium for controlling operation of the conveyor to:

receive, at the electronic processor, second output signals from a second sensor array positioned adjacent to the second sprocket, wherein the second output signals from the second sensor array are indicative of a position of the second conveyor element, and

wherein the determining of the tension state of the conveyor is based also on the second output signals.

18. The controller of claim 17 , wherein the controller further comprises a tension state map used to determine the tension state,

wherein the tension state map associates potential map inputs from the sensor array and the second sensor array with a plurality of potential tension states of the conveyor,

wherein binary values of the output signals of the sensor array and the second output signals of the second sensor array together form a map input, and

wherein the tension state map associates the map input with the tension state.