New at bauma: ScrapeTec Conveyor belts with monitoring system
A conveyor belt tracker with an integrated predictive monitoring system. At the same time, the misalignment of the conveyor belt is continuously monitored and automatically corrected.
Everything OK. at the conveyor belt? In the future, the user will be able to answer this question simply and comprehensively without having to inspect the conveyor system on site. This is made possible by a belt conveyor tracker with integrated sensors, which ScrapeTec - a specialist in optimizing bulk material conveyor systems - developed and presented for the first time at bauma.
Basis: The conveyor belt tracker for detecting belt misalignment
The basis of the system is the ”PrimeTracker” belt tracker, which detects and automatically compensates for belt misalignment (image 1). Even slight misalignment is immediately recognized due to the non-uniform forces that then act on the roller. The cylinder body then pivots automatically in such a way that the belt is guided back to the centre. This works equally with minor and severe misalignment.
In contrast to similar systems, the tracker can move completely freely in a 360 degrees radius during operation and always maintain 100% contact with the belt. Other advantages of the PrimeTracker include the extraordinarily simple installation, works with reversible belts, the low maintenance requirements and the protection of the belt edges and the conveyor belt.
Sensor technology records the meaningful characteristic values
The developers at Scrapetec have integrated robust sensors into this tracker, which thanks to its compact design can be easily integrated into the lower run of existing conveyor systems. In addition to the misalignment, the sensors can also record other central and meaningful characteristic values, for example the belt position, the belt speed and the condition of the belt or the belt connection.
The necessary evaluation of the data is carried out by a compact industrial computer, which is mounted directly on the assembly line in a robust, dust proof and splash proof housing. An external power supply is not necessary. Instead, a generator integrated into the caster generates the energy required. The system thus works completely independently.
Data transmission via radio
This CMS system, the E-PrimeTracker (Image 2), has ScrapeTec presented for the first time at bauma 2022 in Munich. The data recorded by the sensors and processed by the computer is sent wireless, via mobile communications or WLAN, to a control room or to the laptop or mobile phone of the service staff, as required.
An on-site status display, e.g. with different types of warning or indicator lights, can also be implemented. There will also be an app that will give on-site service technicians or maintenance planners mobile remote access to every E-PrimeTracker at the company’s premises.
World premiere: Continuous and comprehensive recording of the operating status of conveyor belts
This world premiere thus creates the prerequisite for continuously and comprehensively recognizing and documenting the ”health” of a belt conveyor (cracks, irregularities at the splicing points...) in the sense of condition monitoring and predictive maintenance - with the aim of to report irregularities and rectify them as quickly as possible. This type of transparency significantly increases operational reliability and reduces the risk of unplanned downtime. At the same time, the E-PrimeTracker automatically corrects any belt misalignment.
Integration of the data into predictive maintenance systems
The processed sensor data can be easily integrated into the preventive maintenance systems commonly available on the market. The user can derive service requirements from the transmitted data, because the sensors reliably detect changes and issue a warning message at an early stage – before major damage or a conveyor break down occurs.
In addition, the E-PrimeTracker collects and documents the recorded data. On the basis of this data, the user can, for example, optimize the way the belt is driven and thus extend its service life.
Successful test series
In various series of tests, the ScrapeTec engineers have proven the practical suitability of the E-PrimeTracker in different load situations from 75 to 225 N and different positions on the belt and various operating states (entry, return, with blocked idler). In each test, the parameters determined by the sensors corresponded to the actually measured value
