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Smart-Idler Presentation
AUTOMATED CONVEYOR ROLLER CONDITION MONIT
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The Problem
Safety Hazard Remove people. El
Damage Conveyor
Conveyor Downtime
Idler failure is very costly for conveyor opera
IdlerFailure
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The Solution
Smart-Idler
Real-time 24/7 automated electronicmonitoring of key idler conditions.
Pre-emptive detection of idler failure.
Integrated into idler body.
Completely wireless.
Maintenance free.
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Features
Energy Harvesting
Rotation Based No Batteries!
Wireless Remote Access
Meshed Radio Network
Auto Discovery
Simplified Identification
RFID Tagging
Electronic Serial Number
Networkable Data Transfer
Back-to-Base Information
Rotation Count Rotational Velocity
Sound Pressure
Bearing Temperature
Install Date
Location
Integrates with PLCs and
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The Technology(1stGen Prototype shown)(2ndGen Prototype nearing completion & requires trials)
RFID
Generator
Mesh Radio
Temp Sensors
Vibration
Rotation SensorSound
Adjustable Mount
FIRST GENERATION PROTOYPE
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The Value of the Smart-Idler
CASE STUDY:
CONVEYOR LENGTH = 800m (cumulative) QUANTITY OF ROLLERS = 2,800 CAPACITY = 10500 tph
Yearly hours of downtime attributed to roller failure = 17hours
Smart idler assumed to allow the prediction and pre-emptive replacement of 65% of roller failures.
Changing out rollers pre-emptively during scheduledmaintenance where isolation is already in place assumedto take only 30% of the time.
COSTS ARE OVER A 1 YEAR PERIOD.
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JUST 1 HOUR OF LOST PRODUCTION AVOIDED IS 10,500 TONNES - $910,000
Roller yearly replacement costs
$0
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
$16,000,000
$18,000,000
Dumb Idler Smart Idler
D
R
T
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$15,000,000
$15,100,000
$15,200,000
$15,300,000
$15,400,000
$15,500,000
$15,600,000
$15,700,000
0 10 20 30 40 50 60 70 80 90 10
TOTALA
NNUALCOSTOFSMARTROLLERS
SMART ROLLERS
TOTAL ROLLER COSTS
TO BREAK EVEN - ONLY 22 SMART ROLLERS AREREQUIRED
PRICE OF OWNERSHIP PER ROLLER BEGINS TO REDUCE AS SOONAS FIRST SMART ROLLER IS INTRODUCED INTO THE CONVEYOR
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Result:
In the previous scenario, with the chosen variables* the Smart-Idler
Generates savings of $7.1M per year (when a conveyor is 100% Converted).
Smart idler setup cost pays itself off when only 22 rollers are converted in the c
Drives a reduction of roller ownership cost from $207 to $89 per unit per year =
roller
*Variables and calculations available upon request
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Recap
Even if Smart-Idler prevents only 65% of roller related unplanned maintenanc
Smart-Idler will detect every pre-failure & failure event, however not all these eacted upon. Assumed 65%.
Saving is approx. $7 Million per year.
There will be reduced requirement for inspections = less human exposure to ope
EVERY SITE IS DIFFERENT. THIS DATA WILL CHANGE DEPENDING ON COLENGTH, CAPACITIES, PRODUCT CONVEYED, DOWNTIME DUE TO ROLL
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THE ROAD FORWARD2nd Gen prototype finalisation and integration with CPS rollers:
Completion: November 2014
Production of trial units and secure on-site trial partners:
Completion: February 2015
Conduct site trials and evaluate data:
Completion:April 2015
Development of Back-End software for PLC, Citect integration:
Completion:April 2015
Roll-out of units on a commercial scale:
Commence: June/July 2015
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Thank you for your time!
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