The Challenge
Prior to installation of the BeltGauge wear monitoring solution, the client was facing several challenges, including limited visibility into belt wear and damage across long conveyor systems (some travelling distances up to 29 km).
The site was using traditional thickness testing methods (such as Physical Sequential (PS) and Partitioned Data Set (PDS)) which only provide 1D cross-sectional measurements and therefore are insufficient in detecting localised damage or wear.
Furthermore, a 350-meter belt rip occurred requiring urgent replacement and redesign.
Why BeltGauge?
Part of the iBelt suite of intelligent conveying technologies, BeltGauge delivers comprehensive belt scanning to detect wear patterns, damage, and changes in belt profile, enabling proactive maintenance and avoiding costly downtime.
The Mobile BeltGauge units implemented at site now offer full-width and full-length scanning, enabling:
- Comprehensive wear and damage detection
- Early identification of belt profile changes
- Proactive maintenance scheduling
- Reduced risk of unplanned shutdowns
This is especially critical for belts which manage the plant’s inflow. A failure here halts operations, exports, and revenue generation.
- Data-driven decision-making
- Predictive maintenance planning
- Improved operational efficiency
A Collaborative Effort
This delivery of the technology-based solution was a true cross-functional achievement, involving multiple teams across the Fenner brand portfolio. Our East Rockingham WA Workshop, in conjunction with the Diagnostic team’s, custom-designed and built the BeltGauge units and associated mounting systems.
On-site installation was carried out by Fenner’s WA Mechanical Service Teams, while diagnostics teams ensured accurate sensor placement. Collaboration with CPS and our ESC team for engineering support enabled compatibility with existing idler systems, further streamlining the process.
Ongoing data collection will be supported by Fenner’s service teams, a testament to the company’s commitment to aftermarket support.
Overcoming Challenges
Executing this large-scale deployment came with its share of challenges:
- Idler modifications: CPS assisted in transitioning idlers from Vee to Flat profiles to accommodate scanner requirements.
- Debris management: High throughput led to equipment clogging, requiring thorough cleaning between scans.
- Data volume: Some scans generated over 39 million data points, causing upload delays and requiring stable internet connectivity.
- Fabrication pressure: Supplier lead times and tight shutdown schedules demanded agile workshop operations.
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