How to effectively monitor conveyor belt idlers in order to avoid production losses?

CONTEXT OF THE PROBLEM

The problem occurs in the following areas: maintenance, crushing, concentrator and operations. It happens as untimely failure. We need an economical, practical and efficient solution. This solution should accurately detect any damages to the idler and the solution should automatically demand its replacement. The solution should be easy to use for the personnel in charge of inspecting and monitoring the idlers' condition. Besides, in case we needed to change the idler, the solution should have a device for it. This device should not be implemented in each frame, except if it's very convenient for us in economic terms given that there are thousands of frames in the circuit. This device should also intervene the conveyor belt system keeping safety during production, and allowing manipulation to the frame. We should be able to detach it from the belt achieving its horizontal location, and separating it safely from the contact of the conveyor belt. This way, it will be possible to remove the released frame.

DESCRIPTION OF THE PROBLEM

Due to this problem, we experience a shutdown of the crushing plant due to girdle cut, or due to girdle fire which are caused by untimely failure of the idlers. Our personnel's decision criteria for detecting potential problems tends to fail. The judgment of our personnel who have to determine whether the idler continues to work, is replaced immediately or should be replaced, is insufficient. Even after performing a visual inspection and determining that a rotary vane is still in a suitable condition to continue working, we have frequent untimely failure of rotary vanes. If the idlers are not replaced in a time, we can experience potential events such as girdle failure or idler fire. All this will cause a loss of production.

FREQUENCY OF THE PROBLEM

The problem occurs once a week, as an untimely failure. This problem stops some parts of the process for 1 or 2 hours.

PARTIAL SOLUTIONS

We need visual inspection of the idlers. We haven't had nor developed a monitoring equipment, nor a robot for rack removal yet.

IMPACT OF THE PROBLEM

Normally, there is a loss of production in the section or area where the problem occurs given that it stops.

QUANTIFICATION OF THE PROBLEM

The problem causes 1 to 2 hours of downtime in a section, once a week.

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