CONVEYING
With MCube CAM, REMA TIP TOP says it is introducing a pioneering innovation in conveyor belt monitoring
where the belt rips and other bottom cover damage is detected. The top cover is monitored right after the conveyor unloading where the top cover damages are detected and the belt thickness is measured. The belt damage and the wear data are stored in a database. Users can easily obtain physical access to inspect and repair the damage with a couple of mouse clicks and automated conveyor control. The belt is driven with full speed to a position where the damage is at pre-defined belt repair station.”
Evers:“ We have a very rigid semiconductor line laser which meets with the surface of belt.
On the other side of the unit, we have a special high speed camera, which is detecting only this thread reference line 500 times a second- the scanning speed is 500 herz. What we detect is transferred into the software interface as digital information, and we can then visualise it as a grey scale image.”
He added:“ The general idea of this HX technology is very simple. Each and every internal or external damage is generating three dimensional surface deflection in the conveyor belt. On the material side and also on the clean side. If we have higher or deeper deflection than 0.2 millimetre, the laser line is precisely following and the camera, just because of this high scanning rate, can generate a very, very precise grey scale image about that. We have to know the rotation speed of the conveyor belt because we have to identify where is the exact damage located. We know the speed from an RFID tag on the edge of the belt, or somewhere in the middle section in the splicing area, just one on the whole belt.”
Becker’ s BRS4.0, smartflow ® & MineView AI
Conveyor systems are a critical components of mining operations, directly influencing productivity, safety, and operating costs. Conveyor belt failures and unplanned downtime remain among the most significant challenges for mine operators worldwide. In response, intelligent monitoring solutions are increasingly being deployed to support predictive maintenance strategies, improve operational safety, and enhance overall system availability.
Becker Mining Systems’ BRS4.0 it says represents a further development beyond conventional belt rip detection systems. By adopting a holistic approach to conveyor belt monitoring, the system enables early detection of critical conditions such as defects, rips, and belt misalignment- issues that, if left unaddressed, can lead to progressive damage or unexpected failures. Early visibility of these conditions allows operators to intervene proactively, reducing the risk of costly repairs and unscheduled shutdowns.
A key element of this approach is the integration of advanced system control in digital platforms. The modular SCADA system smartflow ® provides centralised control, monitoring, and analysis of conveyor systems and other mining infrastructure. Designed as a core component of the Digital Mine, smartflow ® consolidates data from sensors, communication networks, and operational processes into a single platform. Real-time data visualisation, including 3D web-based monitoring, supports improved situational awareness and more effective operational decision-making. Its modular architecture allows smartflow ® to be adapted and expanded to meet site-specific requirements and to integrate seamlessly with additional systems.
The monitoring capabilities are further enhanced through the use of artificial intelligence. Becker Mining Systems’ MineView AI extends conventional conveyor surveillance by applying high-precision visual analytics. AI-based algorithms analyse image data to identify belt defects, damage, or foreign material that may obstruct conveyor operation or cause secondary failures. This additional layer of analysis shifts conveyor monitoring from a reactive process toward a more predictive and condition-based maintenance strategy.
The combined use of BRS4.0, smartflow ®, and MineView AI enables a comprehensive monitoring concept in which processes are not only observed but systematically analysed and optimised. At the same time, AI supports operators and control room personnel by filtering large volumes of data, reliably identifying anomalies, and highlighting critical events that require attention. This targeted support reduces cognitive load on personnel, shortens response times, and improves the reliability of fault detection. As a result, operators benefit from improved safety levels, increased conveyor availability, and more informed operational decisions- key factors in advancing the digitalisation of modern mining operations.
Martin Engineering and the problems of conveyor belt return
Dan Marshall, Process Engineer, Martin Engineering shared with IM his thoughts on the return side of the conveyor which he says may be the most deceptively hazardous part of a conveyor system.“ With long gaps between rollers and carrying no cargo, there is an extensive list of injuries inflicted on workers from the return side of conveyors in the Occupational Safety and Health Administration( OSHA) database. Caused by nip / shear points, belt contact and reach-in hazards from working around a running conveyor, these injuries stem not only from a lack of satisfactory protection of both the worker and system, but also inadequate training.”
He adds that many experts will attest to the fact that efficiency and safety are inextricably linked. Thus, an emphasis on safety translates to a reduced cost of operation and increased production. Clean return systems using modern equipment mean less spillage and cleanup under and around the belt, which mitigates labour costs, downtime and exposure to work hazards. A well-maintained belt return also yields less dust, fewer fouled rolling components and a centered belt entry from the tail pulley into the loading zone.
“ Nip points are created where a moving element of the conveyor machinery meets another rotating or moving component. Based upon common belt speeds and average human reaction times, a shovel or other tool in an entrapment situation will pull the worker using the tool in with it before the person can even let go. The same is true of loose-fitting clothing or long hair when working beside or under a running belt. Shear points occur when the edges of two machine parts move across or close enough to each other to cut a relatively soft material. An example of this is where the belt quickly passes a stationary beam or component, which can trap a limb, abrading it or severing it.”
The fugitive material hazards posed around the belt return begin with the discharge at the head pulley. An insufficiently cleaned belt can cause carryback to drop along the entire belt path and spill into walkways or on the return belt. This produces a trip hazard and a possible violation. In addition, dust can get into cracks and divots in the belt, release along the belt path, and foul gears and bearings of rolling components, causing them to seize and creating a possible fire hazard.
Inadequate cleaning technology and tensioning systems allow carryback to collect directly beneath the discharge zone. If not addressed, material accumulates quickly until the belt runs along the top of the pile, creating carryback across the entire
International Mining | FEBRUARY 2025