'Sensing Idler' optimizes operation and maintenance of belt conveyor systems with intelligent sensor technology
Ensuring the functionality of belt conveyor systems is critical to open pit mining operations. Operators often rely on visual inspections, fixed maintenance intervals or reactive maintenance - intelligent condition monitoring for idlers is not yet available. The disadvantages of preventive maintenance intervals are obvious: The optimal individual point in time is almost never reached, which means that wear parts, for example, are replaced too early in the vast majority of cases. This leads to unnecessary costs and a waste of resources. With condition-based maintenance, replacement occurs when damage is detected. This can result in everything from short, unplanned interruptions to critical and long-term system failures.
Cooperation with the market leading manufacturer of conveyor rollers Artur Küpper GmbH & Co. KG
In close cooperation, Artur Küpper GmbH & Co. KG, a leading international manufacturer of idlers and roller bearings, and core sensing GmbH have developed an innovative monitoring system for idlers in belt conveyor systems, the "Sensing Idler". The Sensing Idler system provides continuous live monitoring of the status of any number of idlers and alerts the operator to unusual bearing temperatures. Planned idler changes can be prioritized or postponed based on individual condition values, without the risk of an undetected defect.
Cloud-based idler monitoring: Sensing Idler Optimizes Maintenance of Conveyor Systems
The core of the Sensing Idler" system is the integration of sensor IoT functionality inside the idlers. The intelligent idlers do not differ from standard idlers in their essential characteristics and can be put into operation without any additional effort. Sensing Idlers are so energy efficient that the built-in power supply ensures that the sensor functions can be used for at least 5 years.
The intelligent idlers continuously send all relevant status information to the cloud for the operator. In addition to a clear presentation of the status in a dashboard, irregularities or even critical statuses are reported to the operator via push notification. If required, these cloud capabilities can be integrated into existing condition monitoring systems to make them even more user-friendly. With this tool, planned roll changes can be optimized and prioritized based on individual condition values, significantly reducing the risk of overheating and resulting unexpected production downtime.
Revolutionary idler monitoring at the Hambach open pit mine: The Sensing Idler" system in action.
The "Sensing Idler" is currently being put through its paces under real conditions in the Hambach opencast mine. The operator of the opencast mine, RWE Power AG, is providing significant support for the pilot phase and is thus making an important contribution to the successful market launch of the product. RWE underlines the importance of environmental protection and sustainability for the company and accepts its responsibility to support long-standing partner companies in the testing of new technologies.
The pilot phase has three main goals:
- Demonstrate the technical performance of hardware and software under real-world mining conditions
- Testing the usability of the system under real-world conditions
- Validate suitability and reliability
The Sensing Idler provides the following benefits to system operators:
- Improved early detection of idler damage: By continuously monitoring idlers, hot runners can be detected early and damage avoided. As a result, unplanned conveyor system downtime can be avoided.
- Increased maintenance efficiency: Intelligent monitoring allows maintenance to be focused on the idlers that are actually damaged. This saves time and money.
- Increased system reliability: By eliminating unplanned conveyor system downtime, system availability is significantly increased.
Smart Technology for Mining: Launch of Sensing Idler at Chile's Leading Trade Show
The market launch of the "Sensing Idler" took place at a trade fair in Chile in June 2024. The innovative system represents a significant advance for the mining industry following the completion of the pilot phase at the Hambach open pit mine. The aim of the pilot phase is to validate all aspects of technical performance, durability and user-friendliness under real-life conditions.
