CONVEYOR TECHNOLOGY
The Flexco Elevate Belt Cleaner i3 is a state-ofthe-art hardware device that has been meticulously designed in partnership with Twisthink
Flexco . “ We are proud to introduce Flexco Elevate . It ’ s the first technology solution of its kind and will quickly bring increased efficiencies and improved productivity to our customers ’ operations .”
Flexco Elevate , created in partnership with Uptake , and industrial AI and IoT data science leader , reduces
the need for on-site inspections and allows operations to access real-time insights remotely from an intuitive dashboard , so users are able to quickly address belt conveyor performance issues and minimise unexpected downtime . The insights pipeline begins by installing a state-of-the-art Flexco Elevate i3 Device to the end of each Flexco belt cleaner where cutting-edge analytics are immediately aggregated and processed . The information is then wirelessly transferred to the Flexco Elevate Dashboard where operations have immediate , remote access to actionoriented insights and service information for all of the Flexco cleaners throughout the operation .
Flexco says Elevate fundamentally alters the way operations are run and the solution ’ s multi-faceted benefits streamline internal processes . They include : n Increased productivity : The Elevate solution makes it easy to manage belt cleaner service n ROI from day one : Data insights are immediately transferred to the dashboard so operations realise operational efficiency from day one n Improved safety : The Flexco Elevate solution reduces the need for dangerous physical inspections along beltlines n Asset management : Digital mapping of installed Flexco cleaners provides visibility of assets for more efficient resource planning n No guesswork : The operations team knows exactly what , when , and where service is needed . n Leverages existing assets : The Elevate Platform works with existing Flexco belt cleaners – no additional investment in cleaners is required n Remarkably easy : Installation and activation in as little as five minutes for a user-friendly experience .
“ With the introduction of Elevate , Flexco is reimagining the ways customers can enhance their operations through innovative solutions and added value to belt cleaners and other conveyor components ,” said Ryan Grevenstuk , Director of Global Heavy-Duty Marketing .
“ Because it has the power to turn complex data into real-world outcomes , Flexco Elevate is able to transform the way operations address pain points – allowing them to make proactive decisions that continually maximise their uptime and productivity .”
Keeping conveyors on track
Scrapetec has added to its range of conveyor components with the new PrimeTracker belt tracker , which , it says , eliminates problems associated with conveyor belt systems , including misalignment , abrasion and belt damage . Thorsten Koth , Sales and Distribution for Scrapetec , explained : “ For optimum performance of a conveyor system , it is critical that the belt always runs straight on the conveyor , without sideways movement . Our new PrimeTracker belt tracker has been designed to automatically guide a conveyor belt back into the correct straight-line position , to prevent costly downtime and component replacement .”
One advantage of the Scrapetec PrimeTracker is that it always operates in the idling position , unless there is sideways movement of the belt , Koth said . This system corrects misalignment immediately by guiding the belt back into the correct position , with no damage or abrasion to the belt or tracker , he added .
“ This is unlike conventional belt trackers that slide over the belt surface causing possible abrasion and belt damage – rather than adopting free rotation ,” he said . “ Conventional belt trackers , with tapered edges , never idle and are always in a braking mode .
“ What ’ s also notable , is the cylindrical shape and pivot bush that allow this belt tracker to swing and tilt during operation and to always be in full contact with the belt . Added to this , the Scrapetec PrimeTracker has the same peripheral speed over the entire surface of the belt , where traditional crowned rollers have different speeds at the centre and edges of the system .”
Other advantages include easy installation , low maintenance requirements and protection of belt edges and structure of the conveyor belt , according to Scrapetec . A strong corrugated EPDM rubber hose protects this system from dust and sand , while the rubber pivot offers soft suspension of the tracker shaft , ensuring extended service life of the system , the company added . This system can be installed in front of every return pulley , above and below the belt .
Kinder Australia believes its K-Commander ® series can alleviate many of the issues that come with conveyor belt misalignment , keeping operations on track while minimising downtime . As the company explains , a poorly tracked conveyor belt can lead to a number of productivity and safety issues . Damage to the conveyor belt itself as well as the conveyor
structure is a major problem . As the belt misaligns , the edge of the conveyor belt is at risk of becoming torn . The conveyor structural damage is also highly likely , which is a significant safety risk . Replacement of both is extremely costly and will require interruption in production and added labour , Kinder says .
Another issue that can come as a result of belt misalignment is material spillage . As well as the cost of product wastage , excess material can increase the risk of personnel slipping , tripping , falling over and becoming entangled . Material spillage can also damage idlers and cause conveyor rollers to seize .
The ideal scenario whereby a conveyor belt tracks ‘ true ’ in the centre , involves idlers and pulleys being aligned , levelled and square to centre line prior to loading the belt , Kinder explains . “ It should be pivoting and rotating freely when the belt experiences any mis-tracking behaviour .” Other options include fixed tracking solutions without a rotating structure .
In order to install any one of the K-Commander series , the belt needs to be monitored to identify problem areas that cannot be solved by making adjustments .
The K-Commander Exceed Series is an all-direction belt tracking solution featuring flexible 360 ° rotational capability , with its separate axial and rotational function allowing for the double axis pivot bush , the company says .
The K-Commander Exceed Series P has been designed with two key stages : n The first focuses on the inner shell which contains the shaft and an engineered pivoting bush allowing the axial movement of the tracker . The inner shell is protected by a flexible EPDM rubber boot ; and n The second stage focuses on the roller bearings , which allows the rotational movement of the tracker . The roller bearings connect the inner shell and the outer shell , and are protected by a labyrinth seal . “ The installation of the K-Commander Control Series is only for the return side , being the most critical surface of the belt in order to maintain belt alignment ,” Kinder says . “ The unique engineered action of the central ball and socket link is encased in a rubber covered steel tube . This protects the internal mechanics and ensures that the belt runs true .”
The K-Commander Direct Series is a pivoting base style , available in both trough and return applications that automatically provide belt centring . The outboard servo rollers cause the idler frame to pivot as they contact the belt edge and this swivel action causes the belt to realign automatically , the company explains .
To further aid belt tracking , Kinder Australia offer rubber lagged rollers ( trough and return ) as an option . The results are better tracking performance ( especially in heavy-duty applications ), increased roller durability against the constant scuffing nature that roller shells in trackers experience and increased belt training response , the company says .
44 International Mining | FEBRUARY 2021