‘Sensing Idler’ optimizes operation and maintenance of belt conveyor systems through intelligent sensor technology
Ensuring the functionality of belt conveyor systems is of critical importance for operational processes in open-cast mining. Operators often rely on visual inspections, fixed maintenance intervals, or reactive maintenance—intelligent condition monitoring for idlers has not been available until now. The disadvantages of preventive maintenance intervals are obvious: the optimal, individual timing is almost never met, meaning that wear parts are replaced too early in the vast majority of cases. This leads to unnecessary costs and a waste of resources. In condition-based maintenance, replacement occurs when damage is detected. This can lead to anything from short, unplanned interruptions to critical and long-term plant failures.
Cooperation with market-leading idler manufacturer Artur Küpper GmbH & Co. KG
In close cooperation, Artur Küpper GmbH & Co. KG, an internationally leading manufacturer of idlers and roller bearings, and core sensing GmbH have developed an innovative monitoring system for belt conveyor idlers: the “Sensing Idler.” The Sensing Idler system enables continuous live monitoring of the condition of any number of idlers and warns the operator in good time, particularly in the event of unusual bearing temperatures. Planned idler changes can thus be prioritized or postponed based on individual condition values without having to accept the risk of an undetected defect.
Cloud-based monitoring for idlers: Sensing Idler optimizes the maintenance of belt conveyor systems
The core of the “Sensing Idler” system is the integration of sensor IoT functionality into the interior of the idlers. The intelligent idlers do not differ from standard idlers in their essential properties and can be put into operation without additional effort. The Sensing Idlers are so energy-efficient that the built-in power supply ensures the use of sensory functions over a period of at least 5 years.
The intelligent idlers continuously send all relevant condition information for the operator to the cloud. In addition to a clear presentation of the conditions in a dashboard, irregularities or even critical states are reported to the operator via push notification. If required, the described cloud functions can also be integrated into existing condition monitoring systems to achieve even greater user-friendliness. With this tool, planned idler changes can be optimized and prioritized based on individual condition values, significantly reducing the risk of overheating and the resulting unexpected production downtime.
Revolutionary idler monitoring at Hambach open-pit mine: The ‘Sensing Idler’ system in operation.
The “Sensing Idler” is currently being put through its paces under real conditions at the Hambach open-cast mine. The operator of the mine, RWE Power AG, is providing significant support for the pilot phase and is thus making an important contribution to the successful market launch of the product. RWE underlines the importance of environmental protection and sustainability for the company and accepts the responsibility of supporting long-standing partner companies in testing new technologies.
The pilot phase pursues three main objectives:
- Proof of the technical performance of the hardware and software under real open-cast mining conditions
- Testing the user-friendliness of the system under practical requirements
- Validation of operational suitability and reliability
The Sensing Idler offers the following advantages for plant operators:
- Improvement in the early detection of idler damage: Through continuous monitoring of the idlers, so-called “hot runners” can be detected early and damage can be avoided. This prevents unplanned downtime of belt conveyor systems.
- Increased maintenance efficiency: Through intelligent monitoring, maintenance work can be carried out specifically on the idlers that actually show damage. This saves time and costs.
- Increased plant safety: By avoiding unplanned failures of the belt conveyor system, plant availability is significantly increased.
Smart technology for mining: Market launch of the “Sensing Idler” at the leading trade fair in Chile
The market launch of the “Sensing Idler” took place at a trade fair in Chile in June 2024. Following the completion of the pilot phase at the Hambach open-pit mine, the innovative system represents a significant advancement for the mining industry. The pilot phase aims to validate all aspects of technical performance, durability, and user-friendliness under real-world conditions.
Product presentation “Küpper Sensing Idler”
Our partner Artur Küpper GmbH & Co. KG presented the jointly developed monitoring system “Küpper Sensing Idler” at Exponor 2024 in Chile
