Flexco has acquired SHG Conveyor Control GmbH, a technology company taking a bold new strategy to prevent belt rips with artificial intelligence.
Modern mining creates mountains of data, though much of it is wasted.
That was the problem that SHG Conveyor Control GmbH founder Dustin Schiller set out to solve.
After almost a decade of working in conveyor monitoring, Schiller was approached by a former client who wanted assistance after a rip event.
“As a technician, you’re interested in the data,” he told ABHR. “I started to analyse the data the client had to find out when the rip happened.”
“The interesting part was that the rip had been preventable. I began digging into the analysis, and based on this, I founded the company with another colleague in 2023.”
At the heart of SHG is artificial intelligence (AI)-powered pattern analysis that detects when a rip is likely to occur.
In the event of a rip or anomaly, the Rip Prevent system generates an output signal based on conveyor-specific thresholds. When combined with a programmable logic controller (PLC), it allows a customer to automatically stop a conveyor before the critical rip event even happens.
The calculation model computes the data 50 times per second and can generate a signal to the PLC system in less than a second, minimising the risk of the event.
By taking a predictive approach, mining operations can reduce unplanned downtime and streamline maintenance planning.
Instead of relying on sensor systems, such as lasers or X-rays, SHG’s Rip Prevent+, now known as the Flexco Elevate Belt Rip Prevention system, connects to the conveyor’s motor to measure the voltage, harmonics, and other electrical information.
Schiller said the data-driven calculation model of the Belt Rip Prevention system has a huge advantage over inductive, magnetic and laser-based systems, because the data-driven calculation model has no risk of wear, is suitable for all conveyor belts, and has low investment costs.
“The motor is the brain of the conveyor,” Schiller said. “A rip has a specific signature, and problems on the electrical side of things also have specific signatures, letting us separate the two events.”
“For example, we had one case where one of the biggest phosphate producers globally installed the Belt Rip Prevention system. It detected a total harmonic distortion failure – the motor was worn out – something that vibration analysis wouldn’t have been able to address.”
The plug-and-play solution has made waves across the industry and is partially why international manufacturer of conveyor products Flexco acquired SHG earlier this year.
The move expands Flexco’s digital portfolio, combining Rip Prevent+ with Flexco Elevate and the Novitool Aero Splice Press with IntelliSplice Technology.
SHG, combined with Flexco’s digital monitoring platform, enables the company to deliver greater value to mining organisations that rely on high productivity.
At first, Schiller had no plans to sell the company he founded but then he saw the opportunities that partnering with Flexco offered.
“They have subsidiaries in Australia, South and North America, Europe, Africa, and have a global footprint. It’s a well-known brand with global technicians that could support the growth of our technology,” he said.
“The decision was to grow faster, but also to become more stable and robust with a sales and technical network in the background.”
Both companies strongly believe that the future of conveyor belt management is digital, connected and data driven.
“The future of conveyor belt management is digital, connected and data driven,” Flexco Australia managing director Rory Cole said. “Rip Prevent+, combined with our Elevate digital belt cleaner monitoring platform enables us to continue our mission of accelerating our ability to deliver enhanced value to those who rely on us every day as their partners in productivity.”
“The mining industry is facing a growing array of challenges, from volatile markets and tougher competition to regulatory compliance and decarbonisation, among many others,” Schiller said.
“Many mining companies are already taking advantage of the significant cost, productivity and safety gains from the implementation of emergent technologies like drones, remote operating centres and AI.”
