• BG10k Steel Cord Rip Detector

    BG10k Steel Cord Rip Detector

    No loops or antennae required
    Any speed or product
    Any belt width or length
    Prevented 3 catastrophic rips across 3 different countries in 2015 alone.

 

Conveyor Belt Rip Detection

Compatible with all belt brands.

Rip Protection

Our goal was to create a state-of-the-art rip detection & protection system that is independent of belt brand, can be retrofitted to existing conveyors and does not rely on notoriously faulty sensor loops.

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Working on ultrasonic technology the BG10k is a sophisticated longitudinal, steel cord belt rip detector capable of detecting partial and full penetration rips without requiring any antennae or sensor loops embedded in the belt carcass.
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BG10k Full Penetration Rip Demo
BG10k Partial Penetration Rip Demo
BG10k in motion

How it Works

How it Works

The BG10k Rip Detector injects acoustic energy into the pulley cover of the target belting at the sensing location and this energy propagates across the belt using the rubber and steel matrix as the transmission medium.

The energy is injected by a transmitter Transducer and sensed by a number of receiver Transducers, located at various positions across the belt. When a longitudinal rip occurs between the Transducers, the level of acoustic energy arriving at a receiver is either reduced or lost completely. This reduction of energy level is used to detect the rip.


Transducers

Transducers

The Transducers can act as both a receiver or transmitter and are interchangeable across the belt width. They are consumable items and a re-build facility is available when they need changing out. The cost of a system is Transducer-dependent and each type of belting performs differently. Therefore, a sample piece of belting from the target conveyor is needed to be shipped to Beltscan to determine the size and thus the cost of the system.

More information on maintenance below.


Communications

Communications

The Main Electrical Enclosure or MEE connects the system to a Site's SCADA and Network (optional). It is the hub of the Rip Detector and is capable of allowing communication to other Belt Guard systems.

Connections include an Ethernet port and a Control Cable that communicates with Site's SCADA system. Data and device configuration parameters are accessed via the Ethernet port.

Technical support is via the Internet over a Site's LAN (VPN or limited network access) or via a dedicated Mobile Broadband modem. This allows the device to be monitored remotely and software upgrades to be rolled out when available.

Our Belt Guard range of products is designed to work together to form a holistic conveyor belt monitoring solution. The MEE is capable of inter-connecting multiple Belt Guard devices. A single software platform is used, Belt Guard Boss, to service the entire range, making upgrading and adding devices a simple procedure.


Robust and Reliable

Robust and Reliable

The Rip Detector has been tried and proven in harsh working environments around the world and is very robust and reliable. A maintenance plan is suggested to ensure full detector functionality, but basic wash-down and maintaining correct alignment is essential.

Current installations include Steel Mills, Iron Ore port facilities, overland conveyors and Copper mines.


Installation

Installation

Installation can be achieved in two ways;

  1. by using one of our product specialists on site to oversee the procedure, or
  2. by using detailed instructions, drawings and plans provided by the manufacturer. Two stages are involved, the first is the installation of transverse framework and hardware and the second, is the termination of power and SCADA and then commissioning/testing.

Installation support is provided via the Internet over a Site's LAN (VPN or limited network access), or via a dedicated Mobile Broadband modem.


IP66 Enclosures and Parts

IP66 Enclosures and Parts

There are two enclosures fundamental to the BG10k Rip Detector plus a set of Transducers and mounts. These enclosures are 304 stainless steel and are rated at IP66 (NEMA 4).

The Main Electrical Enclosure (MEE) should be installed in an electrical sub-station or similar building, away from direct sunlight and heavy wash-down. Some additional weather protection may be needed depending on environmental conditions.


Maintenance

Maintenance

Routine maintenance of the BG10k is limited to regular water wash-down of the Transducers, ensuring the system is kept relatively free from product build-up. Excessive product build-up will lead to premature Transducer failure.

Wear in the Transducers can be monitored via software and a timeline for replacement can be estimated based on trending.

Proper Transducer wheel alignment and free mount movement are critical.


Re-build Service

Re-build Service

The Transducers are consumable items and need to be replaced at the end of their life cycle.

As part of the re-build service, the Transducers must be returned to the Beltscan factory. We recommend holding spare Transducers in store to keep the BG10k online and operational during Transducer re-building.

Service life of a Transducer varies inversely with belt speed, environmental conditions and the quality of on-site maintenance.


Optional Extras

Optional Extras

Optional extras include;

  • IP Camera Video Surveillance
  • Protective weather shields for enclosure
  • Climate control for extreme environments
  • Mobile Broadband modem for remote support and eMail alerts to personnel.

Limitations

Limitations

The BG10k will not operate on all types of belting. Known exceptions include; fabric or PVC belting, belting containing fabric breaker layers, or manufactured from fire-retardant, anti-static elastomeric compounds.


Technical Specifications

Technical Specifications

Application  
Belt Type Steel Cord
Belt Width No limit
   
Front End Enclosure (FEE)  
Construction 304 Grade Stainless Steel IP66
Size (mm) 400 x 400 x 440 (No Weather Shields)
   
Main Electrical Enclosure (MEE)  
Construction 304 Grade Stainless Steel IP66
Size (mm) 400 x 400 x 440 (No Weather Shields)
   
Electronics  
Power Supply  110/220 VAC 60/50Hz or 24VDC
Power  ~100W
Communications  TCP/IP Ethernet and PLC Control Cable
Operating Temperature  -13 ~ 158°F(-25 ~ 70°C), 5 to 95% RH
Storage Temperature  -13 ~ 158°F(-25 ~ 70°C), 5 to 95% RH

Renting Options Available

Renting Options Available

Beltscan has formed a strategic alliance with a major leasing firm and can offer clients multiple funding options.

Flexible fully-maintained renting plans are available on most of the Belt Guard products.