Oil Sand
COUNTRY: Canada
MATERIAL: Oil Sand / Tar Sand
COMPONENTS: 2x iLDR-C, iSDR-C, iDVR, iRPU-F
DESCRIPTION
Volumetric flow measurement and belt alignment tracking.
Extreme environmental conditions (dirt, temperature).
iBeltVOLUME | iBeltSPEED | iBeltALIGN
Radar-based bulk volume, material speed, misaligment measurement
THE NEXT GENERATION IN CONVEYOR BELT MONITORING
THE NEXT GENERATION IN CONVEYOR BELT MONITORING
The iBelt system enhances conveyor operations with high-speed 2D radar scanning for accurate volume flow measurement, capturing cross-sectional views, and providing height and material distribution insights. Its radar-based, contactless speed measurement delivers milimeter accuracy, optimizing belt speeds and preventing slippage without needing recalibration. The iBelt Misalignment feature detects belt misalignment, reducing wear, energy consumption, and spillage risks. Additionally, its freeboard measurement ensures optimal material positioning, minimizing wear and enhancing belt longevity and safety. Overall, iBelt ensures efficient, safe, and cost-effective material handling.
1
Volume flow (m³, yd³, ft³)
97% or better precision material measurement
2
Material speed (m/s, fps, yd/s)
precise material speed measurement
3
Bulk & belt position
center of gravity, freeboard, belt misalignment
SYSTEM OVERVIEW AND ANIMATION
Volume flow measurement / Material speed measurement / Belt alignement measurement / Material freeboiard measurement / Center of gravity & loading peak calculation
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WITHIN ONE SHIFT INSTALLATION
indurad’s iBelt is a ready-to-deploy solution, provided in two convenient packages: one containing the sensors and cables, and one for the compact field cabinet. Its installation and commissioning can typically be completed within a single shift, ensuring a swift and cost-effective deployment. Unlike traditional belt scales, the iBelt requires no recalibration. Additionally, it surpasses optical systems like lasers or lidars by operating effectively under all environmental conditions, including dense fog, dust, rain, and snow.
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VOLUME FLOW MEASUREMENT
high speed 2D radar scan
A 2D radar sensor is mounted above the conveyor and scans a cross section of the passing material. In combination with a fixed speed value of the passing material, a PLC or drive input signal – or at best in combination with our iDVR speed radar – a volume measurement is provided. In addition, height information and material distribution information can be obtained from this measurement.
surface contour for volume measurement
exact measurement due to full surface coverage
spillage & overload detection
enables safe operation and supports blending functionalities
MATERIAL SPEED MEASUREMENT
radar based contactless speed measurement
Based on an indurad Doppler Velocity Radar, the system is able to measure the speed of the material passing underneath. This is the true material velocity value, which is the exact basis for high precision volume scanning. The bulk velocity measurement can also be used independently, for example to optimize belt speeds or to detect material slippage.
no maintenance
no-contact measurement without the need for recalibration
high precision speed measurement
97% or better speed accuracy - much better than other measurement systems
BELT ALIGNMENT MEASUREMENT
contactless belt alignment tracking
Belt misalignment causes significant damage to the belt and reduces belt life. A belt that does not run well in the rollers consumes more power from the drives. The risk of spillage is increased. iBeltALIGN measures the position of the belt at a specific point or along the entire conveyor and is the basis for intervention and optimization.
belt protection
first step to reduce wear on conveyor belts
energy reduction
increasing energy efficiency through correct alignment
FREEBOARD MEASUREMENT
belt alignment and material position
Based on the belt alignment sensor, the system detects the freeboard on the belt to the left and right of the material. This information allows control and understanding of the material position on the belt, providing the basis for more efficient control of transfer points and material flow.
transfer point optimization
direct feedback of misaligned material dispatch after transfer point
belt wear & safety
detect unhealthy material position that increases wear and spillage
ADVANCED DATA
based on cross-section and speed measurement
This set of specific software algorithms is the result of years of development. The advanced data package provides information on material distribution, center of gravity and height distributions for each instant and for historical data.
This allows for a better understanding of bulk processes and belt usage, while optimizing control.
Optimizing belt utilization and flow control
learning, understanding and improving mine-wide belt usage
increase safety & reduce wear
reduce spillage, avoid mistakes in blending processes and predictive maintenance
SELECTED REFERENCES
SELECTED APPLICATION EXAMPLES
Copper
COUNTRY: Chile
MATERIAL: Primary crushed copper ore
COMPONENTS: 12 x iDRRembedded, 12 x iDVR, OPC server
DESCRIPTION
Existing weight scales need to be replaced due to high maintenance costs. Significant improvements in secondary crushing process due to volume based process control with iBelt.
Iron Ore
COUNTRY: Australia
MATERIAL: Iron Ore
COMPONENTS: 2 x iDRR, 1 x iDVR, 2 x iLDR, iRPU-O
DESCRIPTION
Iron ore volumetric measurement.
Belt misalignment measurement and material positon (freeboard).
Improved chute control, full utilization of conveyor belt to shiploader.
Inpit crushing and conveying equipment
COUNTRY: China
MACHINE: IPCC equipment
MATERIAL: Coal
COMPONENTS: iDRR, iDVR, iRPU-I
DESCRIPTION
Belt with high inclination.
Steam coming from the coal.
Moving machinery, permanent vibration of belt, shocks.
Oil Sand
COUNTRY: Canada
MATERIAL: Oil Sand / Tar Sand
COMPONENTS: iDRR, iDVR, iRPU-O
DESCRIPTION
Volumetric flow measurement on chain conveyor.
Measuring volume flow and speed to control mixing box.
Extreme weather conditions (snow, temperature).
Tunneling Machine
COUNTRY: USA
MATERIAL: n/a
COMPONENTS: 2 x iDRR, iRPU-O
DESCRIPTION
iBelt mounted on tunneling machine to measure excavated material volume versus calculated quantity of excavated material (to avoid development of caverns).
Shearer Loader
COUNTRY: Australia
MATERIAL: Coal
COMPONENTS: 2 x iDRR, iRPU
DESCRIPTION
Volumetric measurement with height restriction on chain conveyor.
Explosion proof housings (iCEx/ATEX M2).
No overloading of belt any more due to improved process control.
Potash Mine
COUNTRY: Canada
MATERIAL: Potash
COMPONENTS: iDRRembedded, iDVR
DESCRIPTION
iBelt (volume, speed) in potash mines may be bolt into roof.
Measures productivity of mine segment.
Hard Coal
COUNTRY: USA
MATERIAL: Hard Coal
COMPONENTS: 2 x iLDR, iRPU-O
DESCRIPTION
Freeboard measurement in underground coal mine.
Allows for maximum utilization of belt.
Center of gravity measurement.
Train Tracks
COUNTRY: Australia
MATERIAL: Rocks
MACHINE: Track Renewal and Laying Machine
COMPONENTS: 3x iSDR-C and 3x iDVR
DESCRIPTION
iBelt measures and keeps track of reclaimed and distributed ballast material during track renewal.
Guide-Plates
COUNTRY: Netherlands
MATERIAL: Coal
MACHINE: Barge loader
COMPONENTS: 2x iLDR-C
DESCRIPTION
iBelt measures belt alignment and material freeboard on boom belt, allowing for adapting machine control (guide plate positioning) to improve productivity, and to reduce wear.
Tripper Car
COUNTRY: Chile
MATERIAL: Copper Ore
MACHINE: Tripper Car
COMPONENTS: iDRR, iDVR, iRPU-I
DESCRIPTION
Volume flow on the conveyor belt determines travelling speed of the tripper car, allowing for automation and optimized material blending.
A-Frame
COUNTRY: USA
MATERIAL: Lime Stone/Coal (combined stock pile)
MACHINE: A-Frame Reclaimer
COMPONENTS: iDRR, iRPU-O
DESCRIPTION
iBelt measures material flow directly after boom, allowing for adapting machine control (long travel speed and boom position) to improve productivity, and to reduce wear.
Reclaimer
COUNTRY: Netherlands
MATERIAL: Coal
MACHINE: Reclaimer
COMPONENTS: iDRRembedded
DESCRIPTION
Volume flow measured directly behind reclaimer bucket wheel. Solution provides information to the reclaimer PLC system of the reclaimer, optimizing cutting depths and slew speed.
Tunneling Machine
COUNTRY: Australia
MATERIAL: Iron Ore
MACHINE: Mixing System
COMPONENTS: 4 x iDRR, 4 x iDVR, iRPU-I
DESCRIPTION
Complex mixing process fully controlled by iBelt.
Allows for perfect mixing and thus improves downstream processes.
Significant savings for customer accomplished.
Wood Chips
COUNTRY: Chile
MATERIAL: Wood Chips
COMPONENTS: iSDR, iDVR, iRPU-F
DESCRIPTION
Volume-Flow measurement of wet wood chips.
Coal
COUNTRY: Australia
MATERIAL: Coal
COMPONENTS: iDRR, iRPU-O
DESCRIPTION
Coal stacker controls volume flow, allows stacking of homogenious piles.
Input for dust reduction in stacking process.
Freeboard Measurement
COUNTRY: Australia
MATERIAL: Iron Ore
COMPONENTS: 2 x iLDR, iRPU-O
DESCRIPTION
iLDR contactless freeboard and belt misalignment measurement.
Up to 4000 Hz measurements with mm precision.
Shiploader Belt
COUNTRY: Australia
MATERIAL: Iron Ore
COMPONENTS: iDRR, iDVR, 2 x iLDR, iRPU-O, iCam
DESCRIPTION
iBelt controls surge bin output (optimizing belt load), monitoring belt scale.
Surge Bin Output
COUNTRY: Australia
MATERIAL: Iron Ore
COMPONENTS: iDRRembedded, iDVR, 2 x iLDR
DESCRIPTION
