With its IoT platform Elevate, Flexco Europe has developed an intelligent Industry 4.0 solution that allows operators of conveyor belt systems to monitor their conveyor belts in real time. This gives the operator access to an easy-to-use platform that simplifies and speeds up maintenance thanks to data-based decisions and can even prevent conveyor belt system downtimes through proactive action. If conveyor belts fail unexpectedly in mining or cement plants, this can be expensive for those responsible, as operations come to a standstill for the time being. Elevate is intended to be the right answer to reduce or even avoid such downtimes with a holistic monitoring system.

Previously, employees checked the condition of conveyor belts and their components, such as belt scrapers, on site. This required an inspection of the entire conveyor line. This is not only time-consuming, but also not entirely safe. This is because the technicians may have to squeeze into tight spaces to inspect the system. Once they have identified a problem, they wait for the service team - and for spare parts. This wasted valuable time before the system was ready for use again. In future, Elevate should enable conveyor belt system operators to act proactively rather than reactively, thereby increasing their efficiency.

Collect data, gain insights, derive measures

The platform's data is collected via Elevate devices attached to conveyor belt scrapers. These connect to the cloud at the touch of a button via Wi-Fi or mobile communications, so no cables are required. With an app that the user installs on their cell phone or tablet, they can enter all the conveyor belt specifications when installing the devices on site. Installation, commissioning and monitoring are quick and easy to use.

The app transfers all data to the cloud so that the entries are also directly visible in the i3 dashboard. The employee receives warnings and notifications via this digital and intuitive dashboard: Have interference signals occurred? What is the current position and wear of the conveyor belt scraper? When should the next maintenance be carried out? In addition, there is technical data on the conveyor belt system or the running times of the belt and belt scraper. The data obtained enables operators to make well-founded decisions and derive measures in good time. For example, in the event of a fault signal occurring with a proactive belt inspection on site. This enables operators to rectify problems at an early stage and not only react once a serious failure has already occurred, as was previously the case.

The Elevate system can also be used to optimize maintenance work so that it can be planned more specifically and carried out more efficiently. This is because the performance of the belt scrapers and the condition of the conveyor belt can be assessed at any time and from anywhere without having to send out service technicians. This gives the operator an overview of all the important data and allows them to plan their resources in a more targeted manner. The Elevate system collects data and provides information immediately after commissioning, thus ensuring an immediate increase in efficiency.

This article appeared in issue 3/23