Dependable belt rip detection saves costs, reduces downtime and prevents injury.

Becker Mining has launched the newly developed BRS4.0 belt rip detection system, with advanced features for greater durability, higher efficiency and improved safety.

The new Becker BRS4.0 belt rip scanner, which is a replacement system for the BRS-2 system, continuously monitors a belt conveyor for belt rips and uses real-time loop diagnostics to stop the belt in the event of a problem, reducing damage, minimising downtime and preventing injury.

“The global operation – Becker Mining Systems – developed its BRS belt rip scanning system decades ago, which has proven to be the most reliable solution to conveyor belt problems. Belt rips can quickly and unexpectedly become a costly problem, leading to extended shutdown times in critical conveyor belt infrastructure,” states Rick Jacobs, Senior General Manager (SGM) for Consumables, Becker Mining South Africa. “The BRS4.0 is the latest generation belt rip scanner with new design features encompassing the latest technologies and advanced materials.

“The principal task of this new system remains the same – to detect longitudinal rips on steel cable and fibre conveyor belts as soon as they occur, thus limiting the implicated costs. This highly efficient system provides real-time information that can be accessed locally or remotely.

“Advancements of this system over the previous generation include a new user interface and revised data visualisation system. The updated system can be optionally equipped with an RFID reader to detect embedded RFID chips in the belt. An advantage of this design is that the traditional reference coil is not necessary and commissioning is more flexible.

“For those applications where the BRS controller is mounted on top of the conveyor framework, the new BRS4.0 system can be accessed via a WiFi interface, allowing full functionality on a mobile device. For additional convenience, an LTE modem allows for remote integration via a cellular network.”

To enable monitoring of steel cord belts, induction loops are embedded in the belt structure. Once installed, the BRS4.0 system detects the loops on the conveyor belt and assigns them numbers. It creates a real-time image of the belt and loops to monitor their condition.

The system includes two types of sensors – the BR2010 transmitter and the BR2020 receiver, which are placed under the belt, with a maximum distance of 250 mm. These sensors continuously monitor the condition of the line in real time and if a rip is detected, the BRS4.0 stops the line to minimise further damage and minimise downtime.

The system provides detailed information about loop positions, their status and the last ten status changes of each loop. Other notable features include accurate belt speed measurements (up to 15m/s), real-time graphics, a forward and reverse facility, password protection and a record of the last 10,000 system changes.

The BR1010 control unit, which is the PLC unit that processes information from the transmitter and receiver, visualises the belt status in real time and can be controlled locally via the 15″ touchscreen display or remotely via Ethernet TCP/IP, ModBus RTU and OPC UA. This unit also has a local WiFi interface that can be used to access information via a mobile device. The BRS4.0 has an integrated user access management system for different control levels.

The BR2010 transmitter and BR2020 receiver, which are the core sensors that enable rip detection, have been developed and manufactured entirely by Becker Mining Systems. These robust devices have an IP65 protection rating and are able to withstand operation in extreme environmental conditions, at a temperature range between – 43 °C and + 50 °C. ATEX and IECEx certified versions are also available.

The transmitter is connected to the BRS4.0 control unit and communicates via BTS (Becker Telegram Standard).

The Becker Mining team works closely with every customer – from the initial concept to final commissioning – ensuring the most effective customised solutions for every project.

The local operation also offers maintenance, repair, spare parts and support services throughout Africa.

The BRS4.0 belt rip system enhances Becker Mining South Africa’s extensive range of reliable interoperable communications, automation and safety systems. These systems include distributed antenna configurations, leaky feeder communications and industrial WiFi systems, as well as tagging and tracking systems, real-time location solutions, traffic information and control systems. Becker Mining also offers remote evacuation signalling systems, environmental monitoring equipment and terrestrial radio and data equipment.

Becker Mining offers complete solutions for communication and automation, energy distribution systems, mechanical, electrical and electronic mining products, as well as transportation and roof support systems. These solutions for energy supply, communication and transport, are customised to meet the exact requirements of every customer and also comply with stringent quality and safety requirements.