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71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
I. INTRODUCTION
Conveyor systems form the streamline for
transportation for materials from one work station to
another work station. Belt conveyors are capable of
transferring materials over a large distance. Failure of
conveyor system can cause serious problems like
unscheduled downtime, fire accidents, unwanted
maintenance costs etc in Plants or Mines. Belt
Conveyor systems have three main components, Belt,
Idlers and Pulleys. These three components require
continuous monitoring .This paper suggests a
methodology for continuous monitoring of Idlers.
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
Pipe
650 mm
Nominal
Speed
Belt
6 m/s
Belt width
2400
mm
Idler diameter
Pipe roller pitch
165 mm
2m
40000 hrs
Bearing type
Face length
500 mm
40 mm
Shaft modulus
2.1x105 N/ mm2
Number of Idlers
( Carrying and Return)
25800 idlers
modules
2150
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
1.
2.
3.
4.
Thermo-grapghy
Bearing Sound Monitoring
Smart Idlers
Automated Maintenance Systems
1 Thermo-graphy
Thermo-graphy is a the technique of using Infra-Red
cameras to monitor the idlers on the conveyor. The
temperature of the idler is monitored in this process.
The output is fed to the Central control room which
monitors the Conveyor system. On rise of idler
temperature than its idler by 15-20 Celsius, the roller
can be tagged for replacement.
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
3 SMART Idlers
SMART Idlers are different from the conventional
idlers. These idlers have sensors incorporated in
them. Sensors like RFID and Temperature are used.
These sensors help in monitoring the conveyor
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
51
International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
operators.
The
inspecttion
is
no
ot
able
too
ndition of alll
simultaneoussly provide thhe health con
rolls within a belt conveyoor system. Hen
nce Predictivee
maintenance with conditioon monitoringg systems cann
be used to inccrease the reliiability of the conveyors byy
continuous monitoring
m
oof the idler status in thee
conveyor.
Fig 12 MA
ARbot Idler Predict
P Conveyorr
Fig 144 Maintenancee Trolley for Pipe
NOWLEDGEM
MENT
VI ACKN
I acknow
wledge the im
mmense helpp from my guide
g
P.N.Girisshbabu , Asssociate Professsor, M.S.Ram
miah
Institute of Technologgy Bangaloree, Mr. M.Ram
mesh
AGM (MM-CHP)
(
NTECL, Chhennai and Mr.
C.Sridar AGM (Mechanical Ereection) and Paul
Brades Principal
P
Enggineer- Assett Managemennt at
Roy Hilll. I am also grateful to thhe authors off the
journals whose literaature where referred for this
article.
VII. C
CONCLUSION
N
Fig 15 Iddler Frame Dam
mage in Pipe Conveyor
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
Referrences
[1] PDS
S,Productivity Developmen
nt
Solutionss
provide
solutionss
Idler
Smart
ww.pdsonline..com.au/idler--management
http://ww
[2] SKF
F Idler Sound Monitor Kit catalog
c
[3] BamB
Bino Ultra Proobe 10000 cattalog
[4] The Application of RFID Technology
T
in
n
nsport System
m
Large-sccale Dry Bulk Material Tran
Monitoriing,Yusong Pang Sectio
on Transportt
The prob
blems in the Fig
F 14 and Fig
g 15 can be easily
e
Technolo
ogy
identified
d and monito
ored using th
he SMART idlers
The
Netherlandss
y.pang@
@tudelft.nl,Gabbriel Lodewijks Section off
Transporrt
Engineeriing
University
of
and
Logistics,Delft
L
ft
Techhnology,The
Netherlandss
ijks@tudelft.nnl
g.lodewij
[5]
C
CONDITION
ORING
MONITO
forr
CONVEYORS A T
TOOL for INCREASED
D
identified
d and tagged ffor maintenancce.
Ltd Augu
ust
[6] An Alternativee and (Morre) Effectivee
ology for Idleer Condition Monitoring
M
to
o
Methodo
Enhance Conveyor Performancee by Raman
n
008
Autar,20
[7] CO
ONVEYOR IIDLER MAIINTENANCE
E
PRACTIICES:IDLER
MAN
NAGEMENT
T
SOFTWA
ARE- Warwicck Bell
vity Developm
ment
Fig 17 Idler Tag ffit, Productiv
[8]http:///www.covengg.com/online/d
default.asp?D
Solutionss, Australia.
eptID=24
457&strCheckkSecurity=no
The SKF
F Idler soundd monitor kit and UE Sysstems
Ultraprob
be 10000 havee been chosen
n for a trial by
y the
Organizaation which is going to taake place in near
future. The
T device w
will be chosen
n on the basiis of
performaance after the trial
t
run.
http://cita.orgg.au/showthreead.php?1004--
or-Idler-Inspecction-Images
Conveyo
Suggestio
on for future is to adopt the
t SMART idler
concept as
a it comes along with the Idler managem
ment
software which can bee easily added
d on to the control
software.. Automated Maintenancee trolley can
n be
purchased and can bbe used to caarry out the idler
replacem
ment in the Pip
pe conveyor which
w
is over cross
c
country.
[11] MA
ARbot Idler Preedict catalog
[12] Spid
dler catalog
[13] Management Summary: The Design of an
n
Automattic
S.S.Kalid
dien
53
Mainntained
P
Pipe-conveyor
r
International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.10 No.71 (2015)
Research India Publications; httpwww.ripublication.comijaer.htm
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