Becker Mining has launched the newly developed BRS4.0 belt rip detection system, with advanced features for greater durability, higher efficiency, and improved safety. The new belt rip scanner continuously monitors a belt conveyor for belt rips, and uses real-time loop diagnostics to stop the belt in the event of a problem, thereby reducing damage, minimising downtime, and preventing injury.
“Our global operation, Becker Mining Systems developed its BRS belt rip scanning system decades ago, and it has proven to be the most reliable solution to conveyor belt problems. Belt rips can quickly and unexpectedly become a costly problem, leading to extended shutdown times in critical conveyor belt infrastructure,” says senior general manager, Rick Jacobs. “The BRS4.0 is the latest generation belt rip scanner, with new design features encompassing the latest technologies and advanced materials.
The principal task of this new system remains the same – to detect longitudinal rips on steel cable and fibre conveyor belts as soon as they occur, thus limiting the resultant costs. This highly efficient system provides real-time information that can be accessed locally or remotely. Advancements of this system over the previous generation include a new user interface and a revised data visualisation system. The updated system can be optionally equipped with an RFID reader to detect embedded RFID chips in the belt. An advantage of this design is that the traditional reference coil is not necessary, and commissioning is more flexible.
For those applications where the BRS controller is mounted on top of the conveyor framework, the new BRS4.0 system can be accessed via a Wi-Fi interface, allowing full functionality on a mobile device. For additional convenience, an LTE modem allows for remote integration via a cellular network.
To enable monitoring of steel cord belts, induction loops are embedded in the belt structure. Once installed, the BRS4.0 system detects the loops on the conveyor belt and assigns them numbers. It creates a real-time image of the belt and loops to monitor their condition.
The system includes two types of sensors: the BR2010 transmitter and the BR2020 receiver, which are placed under the belt with a maximum distance of 250 mm. These sensors continuously monitor the condition of the line in real-time and if a rip is detected, the BRS4.0 stops the line to minimise further damage and minimise downtime. The system provides detailed information about loop positions, their status and the last ten status changes of each loop. Other notable features include accurate belt speed measurements (up to 15m/s), real-time graphics, a forward and reverse facility, password protection and a record of the last 10 000 system changes.
The BR1010 control unit, which is the PLC unit that processes information from the transmitter and receiver, visualises the belt status in real-time and can be controlled locally via the 43 cm touch-screen display or remotely via Ethernet TCP/IP, ModBus RTU and OPC UA. This unit also has a local Wi-Fi interface that can be used to access information via a mobile device. The BRS4.0 has an integrated user access management system for different control levels.
The BR2010 transmitter and BR2020 receiver, which are the core sensors that enable rip detection, have been developed and manufactured entirely by Becker Mining Systems. These robust devices have an IP65 protection rating and are able to withstand operation in extreme environmental conditions at a temperature range between -43 and 50°C. ATEX and IECEx certified versions are also available. The transmitter is connected to the BRS4.0 control unit, and communicates via Becker Telegram Standard (BTS).
The Becker Mining team works closely with every customer, from the initial concept to final commissioning, ensuring the most effective customised solutions for every project. The local operation also offers maintenance, repair, spare parts and support services throughout Africa.
The BRS4.0 belt rip system enhances Becker Mining South Africa’s extensive range of reliable interoperable communications, automation and safety systems. These systems include distributed antenna configurations, leaky feeder communications, industrial Wi-Fi systems, tagging and tracking systems, real-time location solutions, traffic information and control systems. Becker Mining also offers remote evacuation signalling systems, environmental monitoring equipment, and terrestrial radio and data equipment.
Becker Mining offers complete solutions for communication and automation, energy distribution systems, mechanical, electrical and electronic mining products, and transportation and roof support systems. Typical applications are in mining and quarrying, manufacturing, food and beverage conveying, packaging, and general conveying.
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