A system for continuously monitoring an apron feeder with multiple units, including: Multiple sensor modules of different types, where each sensor module relates to a specific type of unit of the apron feeder and includes at least one sensor, each sensor configured to measure a separate condition of a unit of the apron feeder to generate sensor data representing the measured individual condition, The base station is configured to collect the sensor data from the plurality of sensor modules and transmit the outbound data based on the collected sensor data: The processing unit is configured to receive the outbound data from the base station, analyze the outbound data to determine whether any unit needs to be replaced or retuned based on the individual status of any unit of the apron feeder, and produce a determinate result for continuously indicating the overall status of the apron feeder, wherein, When the individual condition of the unit does not meet a predetermined threshold, the unit needs to be replaced or re-adjusted. 1. The sensor is configured to wirelessly transmit the generated sensor data to the base station.
2. A plurality of sensor modules including tray module, return roll module, tail wheel module, gear box module and chain module at least one; The tray module relates to at least one tray of the equipment; The return roller module relates to at least one return roller of the equipment: the tail wheel module relates to a tail wheel assembly of the equipment; The gear box module relates to the apron feeder gear box, and the chain module relates to the equipment cycle chain.
3. The tray module comprises at least one tray wear sensor, the return roll module comprises at least one return roll rotation sensor, the tail wheel module comprises at least one tail wheel alignment sensor, the gearbox module comprises at least one gearbox oil monitoring sensor, and the chain module comprises at least one chain sag sensor: The pallet wear sensor is configured to measure the individual condition of one pallet of the apron feeder; The return roller rotation sensor is configured to measure the individual condition of a return roller of the equipment; The tail wheel alignment sensor is configured to measure the separate condition of the equipment tail wheel: The gearbox oil monitoring sensor is configured to measure the separate condition of the oil in the apron feeder's gearbox: The chain sag sensor is configured to measure the individual condition of the circulating chain of the apron feeder.
4. The pallet wear sensor is configured to measure the amount of wear on the pallet due to the object conveyed by the apron feeder; and the processing unit is configured to determine that the pallet of the equipment needs to be replaced when the amount of wear exceeds a predetermined pallet threshold.
5. The return roller rotation sensor is configured to detect the movement of the return roller by measuring the rotation speed of the return roller; and the processing unit is configured to determine that the return roller of the equipment needs to be replaced when the rotation speed is less than a predetermined return roller threshold.