Tag Archives: conveyor belts

Tru-Trac continuing to troubleshoot conveyor belt issues for mining operators

Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , ,

With belt misalignment remaining the biggest headache for conveyor system operators across a variety of bulk material handling industries, Tru-Trac says it has evolved from this valuable niche into a full service conveyor solutions business.

Having patented and commercialised its belt tracker back in 1996, Tru-Trac has leveraged its engineering expertise and market knowledge into a comprehensive range of conveyor solutions – with a global sales and installation network. There remains, however, a ‘magic’ at the core of the business which, it says, continues to surprise customers: its deep understanding and expertise of belt misalignment solutions – belt trackers.

Shaun Blumberg, COO of Tru-Trac Rollers, highlights the serious disruption that belt misalignment on a conveyor can cause. The impact includes spillage, belt edge damage, structural harm, increased power consumption and increased labour costs. Ultimately, this leads to lost production, higher operating costs and even safety hazards.

From its local manufacturing base in South Africa, Tru-Trac has grown to serve markets nationwide and abroad – including some of the most sizeable equipment in operation. One of the world’s largest stacker reclaimers, which serves the coal sector in Germany, also experienced a Tru-Trac moment, according to Jonathan Rogoff, CEO of Tru-Trac.

“They were having significant challenges with belt misalignment – and told us they never had a belt tracker last more than a week,” Rogoff explains. “When we presented our proposed solution, they were sceptical – thinking we were either over-confident or naive.”

Leveraging decades of application data and its in-house engineering expertise, Tru-Trac enhanced its heavy-duty dual-return tracker into an extra heavy-duty (EXHD) model specifically tailored for this customer’s needs.

“This was a demanding application with the 2,300-mm-wide belt running at 9.6 m/s – close to the speed of some of the fastest belts in the world,” Rogoff says. “A year later, our product was still working well, leading the customer to standardise on this Tru-Trac solution.”

Closer to home, a mining company in Rustenburg recently had its production halted for two days after successive failures of numerous belt tracking products. After a site visit to assess the situation, Tru-Trac returned the following day with two of its belt trackers – to replace the five installed competitor products.

“Within 20 seconds, the belt centralised and the problem was solved,” Rogoff says. “Initially, our customer could not believe what he was seeing and was convinced the old problem would return when material was loaded. However, the belt remained true under full load, as we had predicted.”

Blumberg points out that there has been significant growth in the business over recent years, and the company has expanded its local manufacturing to punch above its weight on the global stage. In fact, within the industry, the brand has become synonymous with its product, to the extent that professionals often refer to any conveyor belt trackers as ‘Tru-Trackers’, the company claims.

After the success of its tracking solutions, it made sense to leverage its brand and expertise by diversifying into complementary conveyor solutions. Through its existing partnerships with international conveyor distributors, Tru-Trac began importing well recognised brands to augment its range. This includes belt scrapers and skirting rubbers as well as impact beds.

“This led to us building our own service teams to provide installation and maintenance support for customers, as we were now dealing with equipment that needed servicing,” Rogoff says. “The beauty of our belt trackers is that they are essentially ‘fit and forget’ solutions that need very little attention during their lifecycle.”

Today, there are about 50 Tru-Trac service teams working across South Africa and into the rest of Africa, to support customers. With this growth came an expansion of in-house sales teams, who work from branches in the main mining regions in South Africa and Africa

“This gave us more control over our own destiny allowing us to develop skilled customer-centric teams to service customers as a complete provider of mechanical solutions and services on conveyor systems,” Rogoff says.

Tru-Trac also now supplies its conveyor solutions to over 80 countries globally, including almost every mining country. At its facility in Centurion, near Pretoria, there are now over 100 employees on the manufacturing side alone.

The company’s in-house engineering and R&D capabilities have significantly expanded, with the size of its R&D department increasing fivefold over the past two years. This growth has enhanced Tru-Trac’s engineering and design capabilities, which include custom design and rapid prototyping, showcasing the company’s commitment to innovation and tailored conveyor system solutions.

Rogoff concluded: “One of the rewarding parts of our work is that we provide conveyor solutions that really do deliver what customers require. We still regularly have customers whose jaws drop in disbelief when we solve challenges which they have unsuccessfully been grappling with for years.”

Controlling dust at mine conveyor belt discharge points

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , ,

The design and function of belt cleaners have come a long way. In the past, belt cleaners were rigid, linear pieces of hardware made out of various materials from brick to plastic that earned the name “scrapers” or “wipers” because that is what they did. They had a low operational life, broke or cracked frequently and contributed significantly to belt wear, Todd Swinderman, President Emeritus, Martin Engineering, says.

Modern primary cleaners are usually mounted at the head pulley and made from engineered polyurethane. This specially formulated material is forgiving to the belt and splice, but still highly effective for dislodging cargo, according to Swinderman. Typically supported by mechanical or pneumatic tensioners, the designs require significantly less monitoring and maintenance of blade tension.

Some primary cleaner designs require no tensioning at all after initial installation. The single primary cleaner strips feature a matrix of tungsten carbide scrapers installed diagonally to form a three-dimensional curve around the head pulley and typically delivers up to four times the service life of urethane cleaners without ever needing re-tensioning, he claims.

As conveyor speeds and cargo volumes increase to meet production demands, secondary belt scrapers are often installed immediately after the belt leaves the head pulley to address dust and fines that escape the primary cleaner. Generally equipped with spring or air tensioners that easily adjust to fluctuations in the belt, secondary cleaners are particularly efficient for applications that produce wet, tacky or dusty carryback, Swinderman says.

Some innovative secondary cleaners take a different approach from the standard secondary cleaner. They feature independent 6-in (152 mm) wide blades with carbide tips set on a stainless steel assembly. Each tip is supported on spring-loaded arms at both ends with a wide range of motion that provides equal load pressure across each blade and requires less tensioning over its lifespan. This design absorbs obstructions, responds to belt fluctuations and is able to arc safely in the event of a belt rollback.

Innovations in both blade design and tensioner engineering have improved cleaning ability, increased equipment life, reduced the need for tensioning and blade changes, and decreased labour for maintenance and clean up. Along with lowering the cost of operation, the most noticeable change is less dust along the belt path and in work areas. This improves employee morale and retention and results in better compliance, Swinderman concludes.

Martin Engineering to deliver new replacement cleaner blade program for conveyor belt operators

Bulk handling, Mining equipment, Mining maintenance, Mining services, , ,

Martin Engineering has announced a factory-direct replacement program to deliver freshly-moulded polyurethane cleaner blades for conveyor belts.

Custom fitted on-site and installed free of charge, customers pay only for the replacement blades.

The program from Martin Engineering assures customers of accurately sized and professionally installed replacement blades that are matched to their specific application, providing optimum cleaning performance and service life to minimise the cost of ownership, the company says.

It explained: “Manufactured in-house for the highest quality assurance, Martin’s replacement blades are made with specially formulated, colour-coded urethane to suit virtually any application. The blades have up to 53% more urethane in the wearable area than competitive designs, extending equipment life and durability. To achieve consistent cleaning throughout all stages of blade life, Martin’s patented Constant Angle Radial Pressure technology incorporates a specially engineered curved blade to maintain optimum cleaning performance and efficiency.”

Martin Engineering says it is the only belt cleaner supplier that has designed its own equipment to manufacture moulded blades. This system maximises quality control and eliminates shipping and labour costs by having the new blades delivered and installed direct from the factory.

The company explained: “The need for conveyor belt cleaning is well established, delivering long-term benefits in both safety and production. Properly maintained belt cleaners reduce the accumulation of carryback under the conveyor and minimise dust build up on rollers and other components. Excessive dust and spillage can foul rolling components and cause abrasion on the belt, reducing the life of equipment by as much as 30%. Even though a multiple-cleaner system can be abrasive when in contact with the belt, it contributes less than 5% to the overall belt wear, delivering a significant net benefit.”

Martin Engineering identifies and addresses conveyor idler issues

Bulk handling, Equipment maintenance, Mining equipment, Mining safety, Mining services, , , , ,

On any belt conveyor system that moves bulk materials, the belt must run straight and true to maximise its life, minimise fugitive material and safety hazards, and achieve high system efficiency, Martin Engineering says.

There can be many consequences of a mistracking belt, but all result in higher costs and increased maintenance. Even a slight belt misalignment can lead to a variety of issues, from small annoyances to full-blown catastrophes.

The most obvious effects include spillage and dust that require personnel to do cleanup – unproductive work that introduces risks from activities in close proximity to the moving conveyor. Spillage from non-centred cargo often gets into idlers and pulleys, reducing bearing life and causing them to seize, leading to friction damage on the belt and potentially starting a fire.

A misaligned belt can also come in contact with the stringer, causing fraying, shredding or splice damage. Great lengths of valuable belting can be destroyed with surprising speed, and even the support structure itself can be damaged, Martin Engineering says. A compromised bracket or support can cause a catastrophic idler failure, which could damage other components of the system and require extensive downtime to repair. Further, there is potential for injury from a damaged belt or loose idler, not to mention the increased exposure to injury from too frequent a need to clean.

“I’ve been working around conveyors for 20 years, and I’ve seen thousands of belts,” Martin Engineering Process Engineer, Dan Marshall, says. “I’ve seen just about every problem that can be caused by a mistracking belt, but one thing I’ve never seen is a belt that runs true right out of the box. All conveyors, no matter how well designed and built, have some belt wander.”

A wide variety of circumstances can lead to mistracking, and operators have tried many things to correct the alignment. Some have elected to place an obstacle such as a block of wood in the belt path, so it won’t travel too far out of line. This occasionally improves the situation, but more often it’s just temporary and the belt will eventually slice through the obstacle.

Many operators have realised that pivoting an idler is a quicker and more effective way to steer a belt. This common approach is called “knocking an idler”, striking it with a hammer to move it slightly and realign the belt (see below).

Equipment manufacturers have also designed components to help align a belt, and these solutions can be successful in specific applications. They include specially-shaped rollers, angled idlers and devices that apply pressure to the belt edge to push it back in line.

“While these mechanisms can improve a belt that’s consistently off-centre in one direction, they do not react to dynamic belt movement, meaning that they don’t correct intermittent belt wander,” Marshall continued. “To combat such changing conditions, engineers designed the tracking idler. Unlike the edge correction approach, the device senses belt movement in either direction, and pivots the idler slightly to steer the belt back into position. It doesn’t apply a great deal of force to the edges, which can damage a belt and splices. When the belt is running true, it remains centred, and when it senses a misaligned condition, it gently corrects the belt.”

Unfortunately, to accommodate limited space availability, tracking idlers typically have short sensing arms, according to Martin Engineering. This requires a fairly large belt displacement to create a small movement of the idler. While these designs do tend to improve tracking, there are limits to how much correction they can deliver, and short sensing arms can actually pinch a belt if the idler pivots too far. To combat this, some operators choose to “tie off” a tracking idler to limit its movement. While the practice can help preserve the belt, it doesn’t address significant mistracking, the company says.

To overcome the limitations of existing belt alignment devices, Martin Engineering has invented and patented a Multi-Pivot Belt Tracker, which employs sensors, pivoting idlers and geometry to align a wandering belt. The sensors avoid pinching the belt, and the engineered geometry amplifies any detected misalignment to create a greater pivot.

Multi-Pivot Belt Trainers (see photo at the top) use longer arms than other designs, positioning the guide rolls further from the pivot roller, as well as closer to the belt edge, according to the company. The closer proximity allows guide rolls to sense very slight misalignments and make immediate corrections. Rather than waiting for a powerful mistracking force, the longer arms require considerably less pressure to move the pivot roller. The result is better correction with no pinch points and less wear on conveyor and tracking equipment, for longer and more efficient service life, Martin Engineering says. Specific designs are available for both the load-carrying belt path and the return run.

“Installing trackers is the economical solution, but operators should do a full analysis and consider also addressing other causal issues,” Marshall added. “By focusing solely on belt alignment, plant personnel may miss other opportunities to increase production and relieve some of the burdens on their system.”

Keeping the belt centred and moving quickly is the key to high production, controlled operating cost and a safer workplace.

“Misalignment causes downtime and costs money,” Marshall concluded. “But nothing causes more downtime and expense than a destructive belt fire or other catastrophe as a result of inattention to mistracking problems.”

ScrapeTec to display latest conveyor belt alignment tool at Bauma 2022

Bulk handling, Equipment maintenance, IoT, Mining equipment, Mining services, , , , ,

ScrapeTec is preparing to present the E-PrimeTracker, a conveyor belt alignment tool that, the company says, can sustainably protect people, the environment and conveying technology, at the upcoming Bauma 2022 event in Munich, Germany.

Wilfried Dünnwald, owner and developer of ScrapeTec, plans to present the functionality first-hand at the trade fair.

The PrimeTracker offers a special roller that detects belt misalignment and automatically compensates for it. In contrast to other solutions, the solution is not conical but cylindrical, with the subtle difference ensuring fast and automatic correction if the belt does not run centrally.

The PrimeTracker’s mode of operation is mounted centrally on an axis and can therefore “swing” freely in any direction to react sensitively and directly to the slightest misalignment and, by correcting it, allow the conveyor belt to run optimally again, according to ScrapeTec. lf everything is in order and the belt is running straight, the PrimeTracker simply acts as an idler.

ScrapeTec is now offering a further development: the E-PrimeTracker 4.0. Its self-regulating function on conveyor belts corresponds 1:1 to that of the PrimeTracker, with the E standing for the “electronic added value of this device”, which ScrapeTec’s developers have integrated. This sees the roller additionally equipped with robust sensors that record all relevant characteristic values such as belt position, belt speed or the condition of the belt splice, making them available for monitoring.

If misalignment situations occur that could lead to a possible belt standstill, the operator is warned in time and can take precautionary action. And, even in the worst case scenario, such as a misalignment scenario with belt lesions and impending belt breakage, the operator is indicated in good time.

These warnings are observed via a colour display on the device, which shows the belt running situation from green to red. On the other band, the information from the sensors can also be transmitted wirelessly to a monitoring system in which the control data is displayed.

Bauma 2022 is due to run from October 24-30, in Munich, Germany.

Conveyor Components addresses bucket elevator conveyor belt alignment

Bulk handling, Equipment maintenance, Mining maintenance, , , ,

Conveyor Components Company’s model VA and VA-X bucket elevator belt alignment control tools are helping operators stay on top of potential issues and prevent damage in the bulk handling sector, the company says.

The model VA and VA-X have a rugged, heavy-duty cast aluminum housing (with a specially designed non-accumulating pocket), with both designed to indicate when the head or boot section of a bucket elevator drifts too far out of alignment.

This control device has a sequential two-pole double-break microswitch rated for 20 amps at 120 VAC, 240 VAC, or 480 VAC.

The switch actuation and linkage arms are field-adjustable with a simple 3/32 in (2.4 mm) hex wrench adjustment. The metal roller is sturdy and bi-directional, and designed to survive in difficult environments, according to the company.

The model VA microswitch is rated for NEMA 4 weatherproof, or NEMA 7/9 explosion proof (model VA-X). Epoxy powder coating or polyester powder coating is available as an option, the company concluded.

Martin Engineering expands conveyor training scope with LMS integration

Bulk handling, Careers in mining, Equipment maintenance, Mining safety, Mining services, , , , , ,

Martin Engineering has added new online conveyor training content specifically designed to integrate with Learning Management Systems (LMSs) so users can assign, monitor and certify progress of all participants during its courses.

The new offering from Martin Engineering includes eight self-paced modules that address methods to identify, understand and correct common bulk conveying issues to improve safety on powerful and potentially dangerous systems, while complying with regulations, maximising productivity and achieving the lowest operating costs.

“Online conveyor training is delivering critical knowledge to companies around the world, and that’s never been more important than in these pandemic-restricted times,” Training Manager, Jerad Heitzler, said. “But, even as the popularity of these programs continues to rise, larger firms face challenges integrating the content into their LMSs so they can ensure thorough and convenient training for all employees – at all levels – across multiple sites. These modules create a verifiable record of employee training, so customers can track and confirm the participation of individuals company-wide.”

Organised into 90-120 minute segments, the virtual classes cover topics such as best practices for safety, fugitive material control and belt tracking.

With the training modules easily accessible and conveniently located in company-wide LMSs, the new Martin content gives customers complete control over scheduling and tracking, the company says.

“This is the type of training that everyone should have, and companies no longer need to rely on an outside vendor to schedule individual or group sessions,” Heitzler continued. “It delivers an in-depth and consistent understanding of conveyors and their hazards, ensuring that personnel at all levels can work safely and efficiently around these powerful systems.”

Martin Engineering has been providing training for much of its 75-plus year history, helping customers better control bulk material flows while reducing the risks to personnel. Designed to maximise employee engagement, the modules deliver topic-specific, non-commercial content that can be put to immediate use, and the new format allows even the most remote locations to take advantage, the company says.

The eight modules cover essential subjects that include an introduction to the concept of total material control, with content on transfer points, belting and splices, as well as belt cleaning, alignment and dust management.

“This system is created using a SCORM 1.2-compliant format, so it will integrate seamlessly with most existing LMSs,” Heitzler added.

SCORM is a widely used set of technical standards that provides the communication method and data models that allow eLearning content and LMSs to work together. All eight modules are currently available in English, Spanish and Portuguese, and can be provided in a variety of formats to meet the requirements of specific customers and their LMSs.

“Seven of the eight modules have a test at the end, requiring a minimum score of 70% to move on to the next module,” Heitzler said. “SCORM allows the content to interact with the LMS and leverage any features that a customer’s system has, which could include tracking the progress of each learner, providing reports or issuing certificates of completion.”

He concluded: “With this new effort in place, Martin has taken another step forward in global conveyor training. We’ve emerged as an LMS content provider to deliver greater flexibility and control over employee learning, helping customers attain the highest levels of efficiency and safety.”

Fenner Dunlop addresses critical conveyor uptime with iBelt BeltGauge

Bulk handling, Communications in mining, Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining services, Mining software, , , , , , , ,

Fenner Dunlop has introduced mobile capability to its suite of iBelt conveyor technology with the BeltGauge solution offering a new way for customers from all commodities and conveyor industry applications to accurately monitor health of the conveyor, the company says.

The fixed BeltGauge solution has been installed at multiple sites since its launch in September 2020, with the industry appreciating how lightweight the mobile unit is when compared with competitor products, according to Conveyor Technology Manager at Fenner Dunlop, Sam Wiffen.

“We have been experiencing high interest and up-take with the fixed BeltGauge unit, however we recognised that some customers required a more mobile solution,” Wiffen says.

“In order to be functional for the mobile context, we needed the unit to be lightweight, flexible and adjustable – properties which have been incorporated into the design and are a strong point of difference from competitors.”

The mobile BeltGauge unit is made from 3D printing a wide range of engineering composites and plastics-based compounds. This contributes to the safety of conveyor technicians by reducing manual handling risks on site.

“The segmented mobile BeltGauge design allows us to install the scanning units in tighter spaces, without having to overhang the unit above handrails,” Wiffen says.

Both the mobile and fixed BeltGauge have been designed to meet all customer requirements, regardless of geographic or commodity group, and are applicable for surface and underground mining applications, the company says.

“The mobile BeltGauge is designed for customers with critical conveyors, who are comfortable with periodic data and are more focused on the ability to record belt thickness across a range of operational conveyors,” Wiffen explains.

Unlike traditional manual thickness testing, the mobile BeltGauge provides customers with a full-length profile of the belt. Because of the mobile nature of the unit, multiple conveyors can be scanned in a single shift, according to the company.

Reporting directing into iBelt’s DigitalHub portal means customers have access to same-day results, the company says.

The iBelt mobile BeltGauge is currently in operation with Fenner technicians in the Hunter Valley of New South Wales and Mackay in Queensland, with field trials currently underway in Western Australia.

Sales and Engineering Manager, Shailendra Borade, explains that developments to the mobile BeltGauge also include the ability to collect belt thickness readings while the conveyor is running, allowing customers to conduct maintenance inspections without stopping production.

“For our customers in Western Australia and other similar sites, who operate 24/7 and have very few shutdowns in the year, this means they can scan the belt before shutdown, review the data, and plan and forecast belt changeouts with latest information and improve belt life and asset health,” Borade says.

“This is huge asset for our customers, reducing overall downtime and improving production efficiency.

“Operating in a niche industry, it’s crucial that we are able to differentiate our products and services, while providing added-value to the customer.”

As Fenner Dunlop expands the range of iBelt products, both mobile and fixed applications will be considered, it says.

Conveyor Components tackles belt alignment with latest control solution

Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , ,

Conveyor Components Company has added a Tilt Action (TA) belt alignment control solution to its offering for use on most belt conveying systems and wastewater filter presses.

The model TA is available in weatherproof or explosion-proof enclosures, with 120 VAC or 240 VAC input power rated microswitches, the company said.

This belt alignment control has dry, unpowered 20 amp SP/DT microswitches, or 15 amp DP/DT microswitches, to allow control of four separate output functions. The unit is bi-directional, able to operate in either direction and the red-coloured roller is highly visible from a distance.

The trip points are field-settable with a simple set screw adjustment on the cam, while the housing is cast aluminum, with optional epoxy coating available for corrosive environments.

Hawk Measurement Systems releases OptioLaser L100 and L200 level transmitters

Bulk handling, Mine surveying, Mining safety, Mining services, Mining software, , , , , ,

Hawk Measurement Systems has released new laser level transmitters that, the company says, are ideal for level, distance and position measurement of solid and liquid surfaces.

The OptioLaser L100 (pictured) and L200 Laser Level Transmitters use a laser that is uniquely different due to the very narrow beam that can measure long and short distances at virtually any angle, Hawk says. On top of this, the OptioLaser L100/L200 is made completely of stainless steel and is extremely rugged, built for the harshest of environments.

Leon Botha, OptioLaser Product Manager, explained that the accurate and durable design of the laser sensors was necessary due to the wide range of applications and industries Hawk caters to.

“The OptioLaser sensors can measure anything from a flat metal plate on the side of any overhead crane, to the top of material stored in a silo,” Botha said. “They are ideal for long- and short-range applications where the unit needs to see through a narrow opening or tube.”

Botha added: “These sensors are being used with great success in many areas such as blocked chute detection, material handling, positioning, plastic pellet silos, conveyor belt edge control, ore pass levels and bin levels, to name a few.”

The OptioLaser L100/L200 Laser Level Transmitters are fully programmable and include simple to use software, Hawk says. The lasers can be configured for either distance or level measurement and will be useful in applications such as mining.