ezifix cat presentation- 23rd july 15 rev_0
TRANSCRIPT
Conveyor Automation Technology
EZIFIX MINING SOLUTIONS AND LORBRAND CONVEYOR TECHNOLOGIES – OUR WORLD WIDE COVERAGE
Remote Monitoring– Feedback to the operations centre
Automatic Fault Rectification– Autonomously acting with event logging
Automation– Full control over your conveying systems
Smarter Solutions– Improvements to current work practices,
tooling and technology.
THE EZIFIX CONVEYOR AUTOMATION VISION
THE KEY BENEFITS ON OFFER Conveyor Roller Operational Monitoring and Feedback
– Status and health of all rollers can be monitored from your Control Centre
– Roller change-outs can be planned instead of being breakdown events
– Rollers can be selectively replaced instead of wasteful block idler change outs
– Historical data will allow shut down intervals to be planned more efficiently and effectively
Automated Change-Over of Failed Rollers
– Failed rollers can be automatically switched. Huge benefit for production critical conveyors
– Maximised plant availability and tonnage throughput
– Safe guard against unwanted demurrage costs experienced with ship loading delays
– Limit train loading and car dumping delays
Reducing High Risk Work Practises Associated with Conveyor Maintenance
– Elimination or improvement to practises that contribute to arm, hand, finger and back injuries
– Reduction in scheduled and recorded man hours required for conveyor roller maintenance
Improvements to Manual Work Practises by Offering
– Conveyor rollers with long operational life and light weight options
– Light weight ergonomic tooling and specialised conveyor maintenance equipment
– Fit for purpose specialised tooling customised for any unique situations
SAFETY AND WELLBEING OF ALL PERSONNEL Eliminate Manual Handling
– Automate conveyor systems where previously thought impossible or overlooked.
Reduction in LTIFR (Long Term Injury Frequency Rate)
– Reduce manual handling
– Provide light weight tooling
– Reduce repetitive stress injuries
– Remove high risk work practices
– Eliminate or Engineer the hazards out
PLANT OPERATIONAL IMPROVEMENTS Reduce Unwanted Downtime
– Real-time performance monitoring
– Known health status and pre-emptive failure notifications
Eliminate Unscheduled Breakdowns and Increase Plant Uptime
– Real time data monitoring provides warning of imminent failures for action when convenient
Extend the Length of Plant Operation Between Scheduled Shut Downs.
– Historical Data Analysis allows trending to forecast remaining life to failure and average roller lifespan.
– Shutdowns can be planned accordingly maximising the plants uptime and availability
EFFECTIVE AND EFFICENT MAINTENANCE Elimination Of Maintenance
– Our primary goal is to eliminate as many maintenance tasks as possible by automating systems
Redesign With Smarter Engineering Solutions
– There is always an alternate or better way to be found
– Don’t ever settle for the saying “We’ve been doing it like this for years”
Improvements To Current Practices
– Employing the latest technologies available to the market
– Removing the human factor from maintenance activities
– Use alternative energy sources. Hydraulic or electric actuation installed on previously hand operated or manual tooling
LORBRAND CONVEYOR TECHNOLOGIES- EST 1987 Largest conveyor idler and pulley manufacturer in South Africa
Located across three continents with four office locations
Annual production capacity
– 500,000 to 750,000 idlers
– 2000 pulleys
Manufactured to AS or CEMA standards. ISO 9001, ISO 14001 & OHSAS 18001 Certified
Lowest running friction roller globally (Independent verification by TUNRA and the University of Hannover, Germany)
LORBRAND CONVEYOR PRODUCTS Conveyor Idlers
– Construction- steel, aluminium, composite and hybrid
– Impact, PU disk, HPDE sleeved and rubber disk
– hollow shaft
Conveyor Pulleys
Conveyor Structure
Impact beds
Accessories
LORBRAND SEAL Dry sealing arrangement Double sealed bearings (more
expensive) Frictionless sealing arrangement Self cleaning No grease contamination occurs with
high pressure cleaning or torrential rain
TYPICAL LABYRINTH SEAL Grease filled sealing arrangement Open sealed bearings (cheaper) High friction due to grease filling,
contact seals and bearing grease Not self cleaning Grease contamination occurs with
high pressure cleaning and torrential rain
TECHNICAL DIFFERENCES- BEARING SEALS
TECHNICAL DIFFERENCES- SHAFT MANUFACTURE Lorbrand shafts are drawn and machined as standard. Benefits include;
– Superior manufacturing accuracy
– Minimal bearing misalignment
– Maximises roll life
NB: * Can be as low as 0.5Kn in some configurations, ref TUNRA Testing, ** Composite & HDPE sleeved rollers are significantly quieter >20%*** Data is based on publicly available information or data gained from independent testing.
Lorbrand Competitors Benefits
Running Friction 1.5n* 2.7n*** Lower Energy Consumption
Angular Misalignment 7-mins 10-mins Improved roller/bearing life
Noise <75dB** >80dB Quieter
TIR 0.5mm between 0.55 and 0.7mm less vibration and belt noise
Bearings 2RS 2ZZ Greased for life, no chance of dust ingress
End Caps Welded into shell Welded on edge of shell Less chance of belt tears - Pizza cutters
Composite Housings Friction Welded Press In End Caps One unit - no chance of separation
Warranty Threshold 1.5% 2% Better roller performance
TECHNICAL DIFFERENCES- GENERAL COMPARISON TABLE
ENERGY SAVINGS- LORBRAND ROLLS V’s COMPETITORS
NB: Data is based on the additional cost per hour for 1km of conveyor, at 5cents kw/h.
Results obtained from testing conducted by the University of Hannover, additional case study’s and supporting data can be provided on request.
SMART CHIP- ROLLER REMOTE MONITORING TECHNOLOGY Hardware developed for harsh mine site environment (Electronics- IP66)
Micro Chips and boards are sourced from quality suppliers in UK and Germany
Micro Chips capable of transmitting temperature, noise, vibration and hours of operation
Micro Chips communicate wirelessly to gateways or a handheld tablet
Gateways communicate to site operations or the remote command centre via fibre optic cable, CAT5/6 network, GSM network or anywhere in the world via Satellite comm’s
SMART CHIP- HISTORY AND DEVELOPEMENT All Ezifix Smart hardware and units have been developed over a period of 4
years, having the units tested at mine sites from the Pilbara, South West and South Australia
All Ezifix Smart Micro Chips are installed inside strong and durable Lorbrand rollers
The first smart chip commercial batch ready for testing on the 31st July 2015.
Anticipate chips to be ready for testing in the field by 4th Qtr 2015.
SMART CHIP- GENERAL OPERATION Initial Activation- Infrared torch is used to awaken the chip.
Setup- Tablet is used to load parameters into the chip and record chip details.
Data Collection- Smart chip wakes up once a day and transmits data to the gateways. Gateways have internal data storage capability.
Data Forwarding- Gateways automatically sent data to control center via Ethernet, GSM network, fibre optic cable or manually retrieved with tablet.
Sampling Interval- Chip sampling interval can be user determined I.e Sample interval of 2 minutes* for proposed condition monitoring package.
SMART CHIP- CONDITION MONITORING CONCEPT Purpose built tough notebook with custom CPU for Data Retrieval. Software
developed by Ezifix Mining Solutions
Condition monitoring system comprises of;
– Tablet- Reception up to 50mtrs (ND-LOS) from the Ezifix Gateways
– Gateway- Data storage interface between tablet and wireless TX sender
– Monitoring Device(s)- Multiple field monitoring sensors connected to wireless TX sender.
System is 100% standalone, 24VDC powered or battery pack. No hardwiring needed.
System in design stage, preliminary testing in 2016
STAND-BY-IDLERS (SBI’s) Hardware developed for harsh mine site environment, IP66 rated
All SBI’s are built with heavy duty steel sections. The first manually operated models are still in service 4 years after installation
Rollers can be changed out during maintenance without having to raise the belt
SBI’s are actuated by a 24VDC linear actuator requiring a power source. Rollers can be switched over whilst the belt is operational
Safety locking devices ensure the SBI is locked solid during operation
SBI’s employ the same wireless communication technology as detailed for the previously mentioned smart roller chips
STAND-BY-IDLERS HISTORY AND DEVELOPEMENT The SBI was originally designed as a manually operated device
Automated SBI’s commenced design once actuation technology became available
Automated SBI’s completed final performance verification in April 2015
SBI is ready for commercial production
SMART INTERGRATION- COMPATIBILITY WITH YOUR PLANT Integration to the site Human Machine Interface (HMI). I.e. Wonderware, Citec or your
brand of PLC operating system
Integrating our solutions to your existing network requires low bandwidth wired and wireless communications, options include;
– Remote Area Satellites- Via an agreement with Optus and Ezifix
– GSM- Gateway accepts sim card for connection to telecommunications network
– Fibre optic cable- Connect to existing infrastructure or fresh install
– CAT5/6 network- Connect to existing infrastructure or fresh install
Ezifix Gateways support point to point data transfer. Full Integration requires singular connection to PLC only
Tablets are able to check entire roller inventory by simply walking past one Gateway in a connected array
Compatibility with SAP software for parts monitoring and inventory level tracking
BELT MAINTENACE EQUIPMENT One-piece portable belt lifters (hydraulic)
OR
Versatile portable belt lifters (hydraulic)
LIGHT WEIGHT LIFTING EQUIPMENT Carbon fibre return belt lifting beams and lifters (2016 release)
Aluminium return belt lifting beams and lifters
“It is our goal to eliminate manual handling by inventing light weight solutions for the
materials handling industry”
ENGINEERING, RESEARCH AND DEVELOPEMENT Ezifix R&D team are always striving to improve our products, invent new
solutions to industrial problems and meet the individual demands of our customers. We can customise any of our products to improve capacity, reduce weight further or operate differently.
CURRENT R&D (2016 RELEASE) Customised hydraulic power packs
Carbon fibre light weight componentry
Conveyor belt tracking frame
Triple roller slide-out impact idler frame.
THANK YOU FOR YOUR INTERESTTHE EZIFIX AND PARTNERS TEAM
David Massarotto - Manager Lorbrand Australia - 0409 105 700
Mark Brennan - Manager Director Adwest Group- 0400 870 084
David Torry - Business Development Manager - 0458 882 274
Justen Wright – Engineering and Technical Manager – 0420 904 536
Please direct any questions, comments or feedback about todays presentation to the above representatives
“Tomorrows Technology for Today’s Miners”www.ezifixmining.com.au www.lorbrand.com.au