CONVEYOR TECHNOLOGY
Clemens Panzer , who plays a leading role in the new development as a member of the interdisciplinary team set up for this project . Sensor-based inspection , by contrast , permits data-assisted remote monitoring of system condition , with the result that potential damage can be detected at an early stage and avoided . Another benefit is that “ the data collected will automatically be made available in a digital form in the future via a user-friendly interface . The data can be viewed at any time and permits the demand-driven planning of relevant service periods . Changes in the conveyor condition over an extended period can be analysed significantly better using the stored historical data , and the anticipated service life of the components can also be better estimated .”
To date , the solution has been successfully tested in initial field trials . Further pilot projects with potentially interested parties are planned . The system is scheduled to be operational in the course of 2021 . “ We expect a viable software solution for future service operations to be available in the course of next year ,” says Panzer .
The Incubator operated by startup organisation Copace provided the necessary environment for the rapid validation of technology- and market-relevant assumptions that underpin the concept and for initial data collections and tests for creating the prototype . To enable this to happen , the necessary expertise was assembled in an interdisciplinary team that examined the system ’ s feasibility , viability and attractiveness based on data , interviews with experts and customer feedback and incorporated the findings for the purposes of optimising the product . Recording audio signals , for instance , resulted in the successful analysis of idlers – whereas only a visual inspection was originally planned . The leap from concept to prototype was completed in just two months .
Vayeron ’ s Smart-Idler ® heads to Brazil
Talking of idlers , Australia ’ s Vayeron recently announced a strategic Smart-Idler distribution and product support partnership with major Brazilian automation and technology solutions provider – Tecnologia de Sistemas de Automação S / A ( TSA ). This boosts its presence in a country with some of the largest conveyor-based mines in the world such as Vale ’ s S11D .
Smart-Idler is Vayeron ’ s conveyor technology offering that eliminates belt conveyor roller related downtime and fires and enables targeted and optimised conveyor roller maintenance for operators . Through Smart-Idler significant conveyor maintenance and downtime reduction savings can be realised . Vayeron is rapidly growing the global distribution of its Smart-Idler product line . Users located in Brazil are now able to source Smart-Idler enabled conveyor roller solutions locally through conveyor roller manufacturers located in Brazil with the full confidence that their solutions are backed by the experience , capability and support of TSA . “ The Brazilian market is an important market for Vayeron .
The bulk materials handling operations in Brazil are some of the world ’ s largest with an urgent need to modernise and increase production efficiencies . TSA is trusted by tier one mining and industrial companies to provide on-site automation services and technology road mapping to assist customers in obtaining the maximum benefit from automation and Industry 4.0 technologies .”
Vayeron CEO , Ryan Norris said : “ The alignment of the two companies represents a clear strategic synergy which will enable the accelerated product penetration for the Smart-Idler technology in Brazil . TSA ’ s trusted place among globally leading tier one industrial process and bulk materials handling companies will ensure that end-users can adopt with full confidence that the technology is backed by local expertise .”
“ Our Smart-Idler system for the elimination of conveyor roller related downtime on bulk materials handling conveyors , is receiving significant industry demand from customers located in Brazil . It is important to us to be able to deliver a quality solution through our local partners and to align their strengths with our product and commercialisation strategy . TSA are at the forefront in the local Brazilian market , with also a footprint in Africa – they make the perfect partner for Vayeron ,” Norris said . TSA ’ s Business Director , Rômulo Campos Machado said : “ The Smart Idler solution is totally aligned with the industry ' s digital transformation goals and its advent clearly shows that predictive maintenance on belt conveyors will not be the same . The innovation and quality of Vayeron ’ s solution combined with TSA ' s expertise and experience point to a successful partnership .”
Smart-Idler uses embedded electronic sensor modules to monitor temperature , RPM and vibration any time the conveyor belt is running
Rapid conveyor repairs
With the new two-component repair compound REMAREP ULTRA 10 , REMA TIP TOP says the repair time for minor damage to conveyor belts or elastomer components is considerably reduced . This new product innovation repairs every conveyor belt in a quality comparable to the original material .
“ In the case of unplanned outages , every minute counts , because every minute costs money ,” says Alexander Sedler , Product Manager Belt Repair at REMA TIP TOP , about the new repair material having an exceptionally fast curing time . At 24 ° C the hardness after 15 minutes is an average of 65 Shore A , and after 60 minutes the conveyor belt can be loaded again . The final stage of hardening is usually reached after eight hours . The red material colour of the solvent-free polyurethane being developed and entirely produced in Germany , allows previous repairs to be visually traced and the overall condition of the conveyor belt to be assessed .
At the same time , the belt has optimum material properties even after the repair : the repair paste offers comparable wear properties to the original material as well as resistance to UV rays , oil and diesel fuel . The main area of application is in conveyor belt repair , for example in the temporary repair of damage to ceiling panels and longitudinal cracks in the conveyor belt as well as the sealing of punctures
With the new two-component repair compound REMAREP ULTRA 10 , REMA TIP TOP says the repair time for minor damage to conveyor belts or elastomer components is considerably reduced
40 International Mining | FEBRUARY 2021