Installation of the Sensing Idler at the HES Bulk Terminal Rotterdam
The HBTR terminal in Rotterdam—operated by HES International —is Europe’s largest import terminal for iron ore and coal. The conveyor systems in use operate 24/7 and are a central component of the loading processes. Unexpected downtime is therefore particularly critical—especially for conveyor belts, which often act as bottlenecks.
As part of a test installation, the Sensing Idler – a sensor-monitored idler for condition monitoring – was integrated into an existing conveyor line. The installation is carried out in cooperation between the component manufacturer Artur Küpper GmbH & Co. KG, the operator HES International and the development partner core sensing.
Objectives at a glance
The goal of the collaboration is to test the system under real-world operating conditions and, in doing so, gain insights for potential future applications. The focus is on continuously monitoring the condition of the idler rollers to detect wear at an early stage and to support data-driven maintenance processes. This additional installation serves to jointly validate the Sensing Idler in an industrial setting.
- Monitoring the bearing condition of individual idlers for early detection of potential failures
- Testing the installation and use of the Sensing Idler under real operating conditions
- Collection of data for condition-based maintenance strategies
- Gaining experience in the long-term use of conveyor systems
Technical highlights of the Sensing Idler
- Measurement of bearing temperature, robustly integrated inside the idler
- Self-sufficient power supply over the service life of the idler for more than 5 years
- Self-sufficient gateway with PV power supply for wireless cloud connectivity
- Automatic position assignment of the idlers during commissioning
- Mesh network architecture for data transmission of several thousand idlers
- Installation and replacement of the idler possible without modifying the system
- Access to idler condition data in the cloud dashboard with APIs
About HES International / HBTR Terminal
With an extensive network of terminals, HES International is one of Europe’s leading independent bulk logistics companies – for both liquid and dry bulk goods.
HES Bulk Terminal Rotterdam (HBTR), a company of the HES Group, is one of the largest terminals for dry bulk goods in Europe and is strategically located in the Port of Rotterdam.
HBTR supplies key players in the steel and energy industries and pursues an open, technology-oriented approach by continuously evaluating new solutions to optimize and future-proof its operating processes.
About Artur Küpper
Artur Küpper GmbH & Co. KG is an experienced provider of components and idlers for conveyor systems based in Germany. The company focuses on the continuous development of its product range and tests innovative solutions – such as the Sensing Idler – together with partners as part of selected pilot projects.
As a development partner of Artur Küpper, core sensing provides the sensor and data platform for the Sensing Idler and supports integration into existing system landscapes.
