ONE BRAND ONE SOURCE ONE SYSTEM

SERVICE MATERIAL PROCESSING SURFACE PROTECTION AUTOMOTIVE

BELT THICKNESS MONITORING SYSTEM

The Belt Thickness Monitoring (BTM) system is the first of its kind in the world that is able to measure the overall thickness of

a conveyor belt while the belt is in operation. REMA TIP TOP TECHNOLOGIES developed the BTM system which continuously

measures wear and wear characteristics on conveyor belts. This not only allows for effective planning, but also allows imple-

mentation of measures to control belt wear, thereby prolonging belt life.

REMA TIP TOP TECHNOLOGIES

REMA TIP TOP, as market leaders is focusing on optimizing the use of our products and services. We offer our clients
solutions for their unique operations with the emphasis on profitability and sustainability

REMA TIP TOP TECHNOLOGIES are constantly developing new systems that will significantly prolong the lifetime of our
client’s conveyor belts. Conveyors are the backbone of any mine and belting is typically their greatest expense. REMA
developed the new BTM system to be used on all types of conveyor belts, whilst in full operation.

The system was designed to provide the client with greater insight into the current status of their conveyor belts, by
providing real-time data showing comprehensive detail into the wear and wear characteristic of the belts, allowing
preventative maintenance and thereby limiting potential production downtime to a minimum.

BELT THICKNESS MONITORING SYSTEM

One of the most important advantages to our clients is the increased life expectancy of their conveyor belts. The
new BTM System utilizes ultrasonic sound waves that records over 1000 readings per second in order to generate an
accurate graphical representation of the belt. Together with in-house developed software we are able to identify and
display any form of wear to the belt, be it from impact damage, structural damage, incorrect installation of belt scra-
pers, misalignment of the belt, a faulty idler or even damage by skirting at the loading point.

The BTM system makes use of an RFID tag installed into the conveyor belt indicating a ‘zero’ mark, to allow pin-point
identification of the damaged or worn area. Damage or wear is detected by comparing the result of a scan of a re-
volution of the belt, to the benchmark scan containing historical data. Such damage will then be highlighted by the
system. This allows the user to monitor damaged areas and take corrective action before they become critical. In
doing so our clients are able to:

ÊÊ  Plan for replacement belts effectively, as the

system can accurately predict the remaining belt life.

ÊÊ Plan for a condition based maintenance shut down,

thereby controlling and minimizing potential downtime
resulting in production losses.

A standard flat idler is installed mid-span between

existing idlers, above the belt, where the BTM is to be
installed. This idler is referred to as a ‘calming idler’ and
is installed in such a manner as to induce just enough
tension into the belt to eliminate potential low tension
dynamic vibration.

Ultrasonic sensor array installed on a conveyor belt structure

REMA TIP TOP TECHNOLOGIES OFFER THE BTM SYSTEM IN 3 FORMATS:

Permanently installed systems, whereby a BTM System is installed to monitor critical Conveyor belts within the mine.

Mobile Scanning Systems, whereby the mine purchases Systems that can be moved around the mine to monitor their
critical belts In this instance a REMA service technician conducts the scan and a detailed report is generated and
presented to the client illustrating the progression of any faults identified.

Monthly service contracts, whereby a REMA technician conducts the scan on conveyors as identified by the client.
Typically these scans are performed during maintenance shut downs at intervals as defined by the client. For such
scans a detailed report is generated and presented to the client illustrating new faults on the belt and also the
progression of any faults previously identified.

2· 3 BELT THICKNESS MONITORING SYSTEM

BELT THICKNESS MONITORING SYSTEM

Scan images generated by the BTM System

SYSTEM KEY FEATURES

ÊÊ  The system shows all wear and damage to the conveyor belt, offering cost saving to client.
ÊÊ  The conveyor belt does not have to be stopped in order for the scan to take place.
ÊÊ  The system has zero contact with the belt.
ÊÊ  The BTM System scans all Conveyor Belts, Steel Cord, Plied and PVC belts.
ÊÊ  The system can be installed on new and used belts.
ÊÊ  Multiple belts can be monitored simultaneously in the control room.
ÊÊ  Multiple network connectivity like TCP/IP, WIFI and Serial are available.
ÊÊ  Every second revolution of the belt gets recorded and saved onto disc.
ÊÊ  Unlimited belt image history is stored in the system database to compare historical and latest scanned images.
ÊÊ  Any damage to the Conveyor Belt can be identified accurately using RFID tag and belt length scale provided.
ÊÊ  The system is easy to install and is very low maintenance.
ÊÊ  The System enclosure is IP65 rated and is suitable for all mining environments.
ÊÊ  The system instantaneously generates a belt image after the first revolution.
ÊÊ  Ease of configuration and operation with user friendly 17 inch touch screen interface.
ÊÊ  Software and controller developed and manufactured in-house.
ÊÊ  Operating system available in several languages.
ÊÊ  System is fully password protected.

SYSTEM REQUIREMENTS
ÊÊ  110 / 240VAC 50/60Hz, 15Amp stable power source.
ÊÊ  Calming Idler installed under the return side of the Conveyor Belt under Sensor Array.
ÊÊ  Scrapper to be installed before the sensor array to remove spillage.
ÊÊ  RFID tag installed into Conveyor Belt to stop and start scan.

The BTM System consists of 3 components illustrated below

Control Unit RFID Reader

Ultrasonic Sensor Array

4· 5 BELT THICKNESS MONITORING SYSTEM

SYSTEM TECHNICAL SPECIFICATIONS

Technical Specification

Supply Voltage 110 / 240VAC 50/60Hz, 15 Amp stable power source

Ambient Temperature Range -40° - +70º C
Working Humidity 20 - 90% RH NON Condensing
Cat 5 Copper - (RG-45) Socket (10 100 MHz)
Ethernet Connectivity
Wireless Wi-Fi Connection – 802.11 a/b/g/n
OS – Microsoft Windows 8.1 c/w all critical security up-
dates CAPE-7 Mini PC
OS and Processing Power Processor – Intel Celeron, CPU 1037U, 1.80 GHz, (2 cpu‘S)
Ram – 4096 MB
Hard drive – 500 GB Disk capacity
Monitor 17 Inch touch screen monitor
Ultrsonic Sensitivity 0.34 mm Accuracy
IP 65 Rating – No ingress of dust, complete protection
against contact. Water projected by a nozzle (6.3 mm)
System Enclosure and Sensor Enclosure rating
against enclosure from any direction shall have no harm-
ful effects.
System Enclosure Glands EX e Enviroglands (Pratley)
System enclosure mounting brackets 4 x Mounting brackets on back side of enclosure (13 mm)
2 x Universal ball joint brackets for easy setup and sensor
Ultrasonic Sensor enclosure mounting brackets
adjustments

UHF Alien RFID Reader, POE, TCP/IP and RS-232 c/w enclo-
RFID Tag reader
sure and cable glands.

RFID Tag UHF RFID tag c/w unique address.

COMPARISON GRAPH
Without the use of REMATECH equipment. The possible loss of the full
length of installed conveyor belt with downtime in excess of 135 hours
NOTES

6· 7 BELT THICKNESS MONITORING SYSTEM

REMA TIP TOP TECHNOLOGIES SA (Pty) Ltd
22-24 Lincoln Road, Nestadt Industrial Sites
Benoni
1500
South Africa
Tel: 011 741 2500
Email: info@rematech-za.co.za
Website: www.rema-tech-za.com
Keith Rice + 27 (0) 82 326 8277
Hannes Wakeford + 27 (0) 82 262 4267
Ettienne Bezuidenhout + 27 (0) 73 545 7827
Helgaardt Müller + 27 (0) 76 212 9480