In mining, materials handling is very challenging for engineering and equipment alike. Wherever bulk materials are transported, stored or processed, damage and wear cause unplanned downtime and inefficient processes. Losses can now be avoided with intelligent lining technology. The technology involves a plastic sheet equipped with sensors that monitor the condition of the sheet supplies by the plastics processor Röchling Industrial and the supplier of semi-finished thermoplastic materials, Maizey Plastics.
Lining material made of plastic has been used in mining and material handling for years. There, the lining material protects underlying components and machines and, due to its good sliding properties, ensures the smooth flow of bulk materials. Sensors that monitor processes in mines or in plants are also not new. The plastics processor, Röchling Industrial, has now combined these technologies with Smart Matrox® – the new intelligent plastic sheet equipped with sensors. It not only combines the properties of the lining materials previously used, but it also provides information about the wear and temperature of the material.
Prevents damage due to fires
The use of wear and temperature sensors have proven particularly useful in mining and have already prevented major fire damage. “We have successfully tested both sensor types in our Matrox material and are already providing reliable data for customers with applications in mining and coal-fired power plants. Tested areas of application are chutes and debris beds on conveyor lines, where a sliding sheet under the conveyor belt made from Smart Matrox®, monitors the temperature of the conveyor system. In use, the material has already prevented major damage from overheating and fire,” explains Michal Sladek, Industry Manager Mining – Röchling Industrial. The solution is also suitable for numerous other areas, and the number and placement of the sensors can also be individually adjusted.
SmartMatrox facilitates monitoring components in remote locations – providing a warning system that draws attention to critical factors, like temperature – before failures occur. Image credit: Andrey Radchenko | istock.com
Important warning functions
Topics such as pro-active and predictive maintenance and automated spare parts supply, can also be implemented much more easily based on intelligent lining technology. “Our experience of the solution, especially in remote locations where material monitoring is complex, has been excellent. The material provides an important warning function and enables easy monitoring, even remotely,” says Sladek. The sensors in the sheet emit a signal when predetermined limit values are reached. The replacement of components can then be scheduled in time.
The sensors are integrated into the sheet during the manufacturing process. While wear and temperature sensors have already proven themselves in mining, other types of sensors can also be integrated into the sheet, at the customer’s request, to measure different parameters such as water flow, loading pressure or noise level. All measured data is collected by a so-called SmartBox and made available to users on a platform. A dashboard or mobile device can be used to retrieve and represent any desired data.
‘Intelligent Mining: Smart Products’ have been developed as intelligent plastic components equipped with integrated sensors to permanently monitor the important process data of a component. Image credit: Röchling Industrial
Industrial, Smart Products
At Röchling, ‘Industrial, Smart Products’ are components equipped with integrated sensors to permanently monitor the important process data of a component. Smart Products such as the Smart Matrox mentioned above, form the basis of an early warning system that draws attention to critical factors before failures occur. In this way, automatic ordering processes can be initiated, and components can be replaced before they fail. Smart Products from Röchling are designed as ‘plug and play’ and are delivered ready-to-install.
Smart Plastics
Röchling Industrial also supplies identifiable and authenticated plastics. These Smart Plastics contain tiny marker particles that provide every component with an unmistakable identifier. In this way, it can be unequivocally determined if a product is an original component. Customers gain greater process reliability in the operation of systems: unlawful complaints can be avoided and the SmartMarker particles provide reliable counterfeit protection. The markers are invisible and do not affect the technical properties of the material.
Smart Plastics with marker particles can be integrated into various Röchling Industrial products. It is also available for the Matrox lining material if desired.