CONVEYING
Becker builds on belt rip detection success with BRS4.0
With nearly 2,000 running installations worldwide , the Belt Rip monitoring system or BRS2 from Becker Mining Systems is one of the leading Belt Rip Detection Systems for both underground and surface applications . For example , the world ' s longest overland conveyor belt located in South Africa , with a length of more than 55 km , is monitored and protected by multiple BRS2 systems . In addition , more than 25 systems have been installed at one of South Africa ' s leading coal mining companies and 35 systems at a well-known platinum mine in Africa . Designed for particularly harsh environments and climates , Becker Mining Systems also offers an Extreme version of the BRS2 , specifically designed for very cold regions , with temperatures well below the freezing point .
Once installed and configured , very little maintenance and servicing is required . As a result , some of the BRS2 systems have already been in operation for more than 15 years , impressing with their reliability and the associated low operating costs .
Accordingly , the challenge for the developers at Becker Mining Systems was to make the BRS2 even better in its new version . “ We asked our customers what they considered to be the biggest advantages of the BRS2 and then developed it further according to their wishes and suggestions " explains Jonas Maximilian Becker , CEO of Becker Mining Europe . " For example , the TCP / IP connection for remote monitoring in particular was repeatedly mentioned as a major advantage . The result is the new BRS4.0 system , which offers extended interfaces ( TCP / IP , OPC UA , RS485 ) for remote diagnosis and control and can thus even be operated via tablet on a mobile basis if desired ." The official launch of the new BRS4.0 system is scheduled to be in the first half of 2023 .
In addition , BRS4.0 now also offers an RFID extension and , just like its predecessor system , can be integrated into existing installations . BRS4.0 can also be connected to SCADA systems already in use and provides detailed information in real time .
The user interface is also new and has been significantly revised . “ The challenge here was to design the interface in such a way that , in addition
Installed Becker Mining Systems BRS2 transmitter and receiver units
to the usual control devices and the PC systems of an IT centre , it should now also be usable on touchscreens of the new BRS master panels and thus logically also on tablets ,” says Pascal Berndt , Software Developer at Becker Mining Europe , describing the new UI . “ It was also important to us that the changes to the layout did not deviate too much from the previous system . Even though the old user interface is now a bit outdated , our customers appreciate its simple and clear use , which we of course wanted to maintain despite many new features .” Belt operators can see the system ’ s status at a glance and easily query event logs , loop status , and causes of belt shutdowns , reducing belt downtime .
In addition to the software and technology innovations , the new BRS4.0 also offers all the benefits of its predecessor model : for example , the system has again been developed for extreme environmental conditions and can be used in temperatures ranging from -43 ° C to + 50 ° C . In addition , belts with speeds of up to 15 m / s can be flexibly monitored in any direction of travel and the total number of coils required to protect the conveyor can be determined as needed : If embedded in short distances ( eg 20 m ) in case of a rip , the maximum tear will only be 20 m . overland conveyor for more than two hours without any transported material , resulting in significant energy wastage . From there , ABB was able to start a discussion around how more efficient conveyor control could be deployed to reduce both speed and energy . “ We also discovered the motor currents on the same pulley on a long conveyor were not similar , an indicator of inefficient load sharing of motors , which can lead to inefficient operation or damage .”
The data-driven consultancy model can also be used to calculate the ‘ real ’ efficiency characteristics of drives based on a company ’ s own process data ( load , torques , temperatures
etc ). This can then be used to identify optimal process parameters and analyse the general configuration / set-up of the conveyor , including a comparison between gearless conveyor drives ( GCDs ) and geared alternatives .
“ With GCDs , we saw a reduction in energy consumption of more than 6 % compared with the
5000
successful chutes operating worldwide
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FEBRUARY 2023 | International Mining 67