Current product offerings for rip detection of conveyor belts use copper wire loops or antenna that when being cut or torn, would send a signal to stop the conveyor belt and prevent a further rip. These old analog systems have no intelligence and are prone to broken loops.
The EMSYS LSRS is an intelligent RFID-based “SmartWire” rip detection and monitoring solution. Unlike traditional loops that expect a signalevery set distance, SmartWires and are able to hold data such as a unique identifier, position in the belt, serial number, and manufacture and install dates.
The LSRS monitoring unit can also read most belt manufacture loops or antennae which provides a cost-effective and long-lasting solution for both new conveyor belt installs and retrofitting of old belt with broken loops. The LSRS has an IP-65 rating, is ATEX certified and UL and CE approved.
ARCHITECTURE & TECHNOLOGY
The LSRS is a digital-based monitoring solution, not the analog relay of older loop monitoring systems which enables; a greater precision on the speed sampling to be read dependably and instantaneously to the PLC and integrate with the other EMSYS Systems such as WSR and BSG (Belt Steering Gear).
The LSRS Receiver and Transmitter units read a much larger area of the loop which enables it to read other manufacturer loops. The LSRS is the only digital rip detection solution that can work with and supplement or replace other manufacturers broken loops, but no other rip detection system can read the SmartWire system.
The SmartWire system is available in two forms; one for being manufactured into a new belt and one encased for retrofitting into existing belts. The heart of SmartWire technology is a braided Kevlar core spiral wound with wire for optimum conductivity and durability. The ends are encased in resin to secure the soldered joints and the wire is stitched onto an impact resistant, strong and flexible breaker fabric, making the SmartWire less likely to break. SmartWire has a 1-year standard warranty on its construction.
The LSRS with SmartWire can be retrofit into an existing belt with broken loops quickly given its smaller size and linear design. Each SmartWire can be placed within 40 minutes versus a 6 hour average for most other rip detection loop replacements. This provides a significant cost savings of time and labor in getting a rip monitoring and detections system in good operating condition quickly. There is an LSRS Retrofit kit available containing a Rubber Skiver, winch,vulcanizing press and control box.
- LSRS can read other manufacture loops, but their systems don't read SmartWire®
- Retrofitting SmartWire is relatively quick to install and very cost-effective
- The receiver coverage of the portion of the loop is larger than traditional antennae
The Receiver-Processing and Transmitter units detect the individual SmartWires, their position and their data in the conveyor belt and feeds the information into a PLC unit or a tablet application.
Monitoring of the belt rip detection can be done via a tablet application and Bluetooth signal. The monitoring data can also be incorporated into the site control operations.
SmartWire is constructed of a Kevlar braided core, spiral wound for conductivity, with resin-encased joints and stitched onto impact resistant breaker fabric. The version shown here is meant to be installed in new belt. A retrofit version, ready for vulcanization, is also available.
EMSYS LSRS and SmartWire is compatible with and able to read existing loop systems of most of the major belt manufacturers such as Coal Control, Becker, Contitech and Fenner Dunlop.
Existing belt with or without broken loops can be retrofit with SmartWire and the LSRS system quickly and more cost-effectively than other rip monitoring loop solutions. A SmartWire can inserted and ready for use in ~40 minutes.
LOOP SURFACE COVERAGE
The LSRS digital transmitter and receivers can read a greater surface area of the loop due to our highly engineered digital technology. This larger scanned area helps loop readability and prevent false positives, even in the harshest environments.
SmartWire Data captured:
- Belt Speed
- Belt Position
- Belt position from previous loop/smart wire to the next
- Health Monitoring (Watchdog)
- Signal strength of each specific loop/smart wire on learned cycle vs most recent
- History of Alarms/Warnings that have been accepted
- Location of Sync tags and distance until we expect to see them again (home position)