Predictive Maintenance Solution for Mining Conveyor Systems

REDUCE OPERATIONAL DOWNTIME, UNPLANNED MAINTENANCE AND ASSOCIATED COSTS BY MONITORING CONVEYOR SYSTEMS REMOTELY AND IN REAL-TIME

Idler failure is the leading cause of conveyor system downtime and the primary reason behind belt fires.  Our predictive maintenance solution monitors temperature, rpm, bearing vibration and shell wear to identify potential failures before they happen.

Industry Challenge

Industry Solution

HOW IT WORKS

COMPLETELY WIRELESS

COST EFFECTIVE TO INSTALL

PROVIDES REAL-TIME DETAILED DATA

INDUSTRY CHALLENGE

CONVEYOR SYSTEMS ARE CRITICAL TO THE MINING INDUSTRY AS THEY TRANSPORT BULK MATERIALS ACROSS VAST DISTANCES.  SYSTEM MALFUNCTIONS CAN HALT PRODUCTION AND SERIOUSLY IMPACT PROFITABILITY.

Idlers are critical moving components of the conveyor mechanism and it takes only one worn or failing idler to cause damage, stoppage or even a fire.  

Catastrophic damage and unplanned downtime translate to significant costs for the mining operator. 

Problems with Manual Monitoring 

Manual monitoring of conveyor systems is labour intensive, expensive and not always 100% effective.  The vast distances involved and the potential dangers associated with manual inspections result in faults sometimes being missed.

LEARN ABOUT TITAN ICT’S INDUSTRY SOLUTION

MANUAL inspections are SLOW, LABORIOUS, unreliable and potentially dangerous

Mining conveyor systems present mechanical hazards and they often cover vast distances, meaning manual inspections are regularly conducted in remote, harsh conditions.

INDUSTRY SOLUTION: Wireless Predictive Maintenance Using Smart Idlers

Predictive Maintenance Solution for Mining Conveyor Systems

Titan ICT’s predictive maintenance solution is a game changer for the mining industry because relevant personnel can be notified about ‘hot-spots’ and roller failure indicators before catastrophic malfunctions arise.

The completely wireless system continually monitors temperature, vibration, rotational speed and shell wear in real-time and can even detect the early stages of wear and tear.

The autonomous system provides an early warning if parameters start to exceed normal operating conditions. Instant alerts about unsafe temperature rises in the roller bearings, significantly lowers the potential for fires.

Data-driven insights can be viewed from the control room, reducing exposure to the mechanical hazards associated with manual inspection methods.  

MAIN FEATURES:

  • Wireless
  • Remote
  • Intelligent
  • Autonomous
  • Cost-effective
  • Long service-life
  • Reliable

INTELLIGENT CONDITION MONITORING

The autonomous system provides real-time
conveyor condition monitoring relating to:  

TEMPERATURE

VIBRATION

ROTATIONAL SPEED

SHELL WEAR

HOW IT WORKS

Sensor Equipped Idler Embedded within Roller

THE IDLER IS A SUBCOMPONENT OF THE ROLLER

The idler, which is equipped with a sensor, is embedded within the roller during the manufacturing process. The sensor module is designed for a long service life (10+ years).

The idler harvests power directly from the rotation of the roller in which it’s housed. From there, it wirelessly relays ‘condition data’ via a mesh radio network, therefore no special wiring is required.

The transmitted data can then be monitored from the control room where personnel can receive unparalleled insights into the condition of conveyor rollers.

keep maintenance costs down and production up

Gain data-driven insights into the condition of conveyor rollers to prevent failures before they happen.  

Summary of Benefits

  • Increase plant uptime
  • Maximize productivity
  • Reduce OPEX
  • Reduce risk of plant failure
  • Lengthen life of assets
  • Lower maintenance costs
  • Improve operational data
  • Redirect manual inspections to alternative tasks
  • Reduce safety risks associated with manual inspections

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