Smart-Idler™ Presentation

AUTOMATED CONVEYOR ROLLER CONDITION MONITORING

Idler Failure Damage Conveyor Conveyor Downtime .The Problem Idler failure is very costly for conveyor operators. Eliminate Risk. Safety Hazard – Remove people.

• Integrated into idler body. • Pre-emptive detection of idler failure. • Completely wireless.The Solution • Smart-Idler™ • Real-time 24/7 automated electronic monitoring of key idler conditions. . • Maintenance free.

Features • Energy Harvesting • Back-to-Base Information • Rotation Based • Rotation Count • No Batteries! • Rotational Velocity • Wireless Remote Access • Meshed Radio Network • Auto Discovery • Simplified Identification • RFID Tagging • Electronic Serial Number • Networkable Data Transfer • Sound Pressure • Bearing Temperature • Install Date • Location • Integrates with PLCs and Citect .

PATENTS PENDING The Technology Temp Sensors (1st Gen Prototype shown) (2nd Gen Prototype nearing completion & requires trials) Mesh Radio Rotation Sensor RFID Sound Sensor Generator Adjustable Mount Vibration Sensor FIRST GENERATION PROTOYPE .

The Value of the Smart-Idler™ CASE STUDY: • CONVEYOR LENGTH = 800m (cumulative) • QUANTITY OF ROLLERS = 2. • Changing out rollers pre-emptively during scheduled maintenance where isolation is already in place assumed to take only 30% of the time. • COSTS ARE OVER A 1 YEAR PERIOD. .800 • CAPACITY = 10500 tph • Yearly hours of downtime attributed to roller failure = 17 hours • Smart idler assumed to allow the prediction and preemptive replacement of 65% of roller failures.

400 COST OF LOST PRODUCTION DUE TO ROLLERS $8.$910.500 TONNES .Compared with SMART-IDLER™ ASSUMED 100% OF CONVEYOR IS CHANGED OUT TO SMART ROLLERS BEFORE AFTER COST OF ROLLER REPLACEMENTS OVER ONE YEAR $78.6M TOTAL COST OF ROLLERS PER YEAR $8.400 COST OF ROLLER REPLACEMENTS OVER ONE YEAR $70.000 OF SHIPPED ORE .5M JUST 1 HOUR OF LOST PRODUCTION AVOIDED IS 10.875 COST OF LOST PRODUCTION DUE TO ROLLERS $15.525.763.578 TOTAL COST OF ROLLERS PER YEAR $15.

000.000 $10.000 Total costs $6.000.000 OF SHIPPED ORE .000 $14.000 $4.000 Direct Roller Cost Roller lost production costs $8.$910.000 $12.500 TONNES .000.$18.000 $0 Dumb Idler Smart Idler Roller yearly replacement costs JUST 1 HOUR OF LOST PRODUCTION AVOIDED IS 10.000 $16.000.000.000.000 $2.000.000.000.

700.600.000 0 10 20 30 40 50 SMART ROLLERS 60 70 80 90 100 .000 $15.400.200.000 TO BREAK EVEN .ONLY 22 SMART ROLLERS ARE REQUIRED Total Roller Cost (SI + Dumb) Dumb Roller Cost $15.TOTAL ROLLER COSTS $15.000 $15.300.000.000 $15.500.000 PRICE OF OWNERSHIP PER ROLLER BEGINS TO REDUCE AS SOON AS FIRST SMART ROLLER IS INTRODUCED INTO THE CONVEYOR TOTAL ANNUAL COST OF SMART ROLLERS $15.000 $15.000 $15.100.

with the chosen variables* the Smart-Idler™: • Generates savings of $7. • Drives a reduction of roller ownership cost from $207 to $89 per unit per year = $118 Saving per roller *Variables and calculations available upon request .1M per year (when a conveyor is 100% Converted).Result: In the previous scenario. • Smart idler setup cost pays itself off when only 22 rollers are converted in the conveyor.

$7 Million per year. DOWNTIME DUE TO ROLLERS etc… . however not all these events will be acted upon. • Saving is approx. • There will be reduced requirement for inspections = less human exposure to operating conveyor. THIS DATA WILL CHANGE DEPENDING ON CONVEYOR LENGTH. EVERY SITE IS DIFFERENT. CAPACITIES.Recap • Even if Smart-Idler™ prevents only 65% of roller related unplanned maintenance: • Smart-Idler™ will detect every pre-failure & failure event. Assumed 65%. PRODUCT CONVEYED.

Citect integration: Completion: April 2015 Roll-out of units on a commercial scale: Commence: June/July 2015 .THE ROAD FORWARD 2nd Gen prototype finalisation and integration with CPS rollers: Completion: November 2014 Production of trial units and secure on-site trial partners: Completion: February 2015 Conduct site trials and evaluate data: Completion: April 2015 Development of Back-End software for PLC.

Thank you for your time! .