Belt Conveyor Monitoring

4B has a wide range of sensors for monitoring the various parts of your belt conveyor. The most common areas for monitoring include: bearing temperature, speed / motion, belt alignment and level / plug indication .

All of 4B's sensors can be connected to our hazard monitoring systems.

Belt Conveyor Monitoring

Sensors

Bulldog

The Bulldog alignment and rip detection switch is an electro-mechanical system designed to detect dangerous misalignment of the conveyor and also detection of belt tear damage. The switch will detect horizontal misalignment of belts when contact is made with the roller, the roller arm will be forced to pivot by the belt activating a switch at 20º to trigger an alarm, and 35º to trigger a shut down procedure of the conveyor. The sensors are usually installed in pairs on opposite sides of the belt.
A steel flexible wire is set below the running conveyor belt approx 20-30mm attached by a rare earth magnet at each end. If the belt is ripped or damaged the wire is pulled away releasing the magnet connection which in turn will activate a switch.

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Touchswitch™

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Touchswitch™

The Touchswitch is an electro-mechanical limit switch with no moving parts, which detects tracking and misalignment problems on bucket elevators and conveyors. When a belt misaligns or a pulley moves over and contacts the sensor, the built in solid-state electronic circuitry detects the lateral force of the belt or pulley and activates a voltage free solid state relay output. This output signal is used to immediately alarm and ultimately shutdown the machine.

The face of the sensor is made from hardened and annealed stainless steel, not soft brass or aluminium, so wear life is longer when a belt contacts it. The Touchswitch is not affected by dust or material build up and will still work when completely covered by material. An external test wheel allows for quick and simple sensor/system testing. The sensors are usually installed in pairs on opposite sides of the machine. The sensors can be connected directly to a PLC input, or for greater safety, to a central independent monitoring system, such as Watchdog Super Elite, IE-Node or the T500 Hotbus system.

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Pullswitch

The Pullswitch is a failsafe taut wire emergency pull cord safety stop switch for open conveyors.

PVC coated steel pull wires and pigtails connect between the switches to provide easy installation and continuous emergency stop access along the length of the entire conveyor. Pullswitches can be installed at 50m intervals, reducing overall system cost. Quick location of a tripped switch is provided by a standard reflector or optional flag marker, and the tripped signal can be wired back to an indicator panel or PLC.

The Pullswitch is a taut wire device, so if wire tension is lost the unit will trip. This design provides a secondary level of safety protection if the pull wire is damaged, or becomes slack.

The Pullswitch’s IP65 / NEMA 4, 4X, 9 rated enclosure is made from polycarbonate and stainless steel, making the housing corrosion resistant and weatherproof. A total of six positive break contacts inside the Pullswitch offer unique operation and control. Two independent cam operated switches with snap action mechanical operation are provided for conveyor shutdown, and four additional micro-switches signal for a slack wire alarm.

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Binswitch Elite Capacitive Sensor

Detects level or plug situations for bulk granular solids or liquids in tanks, bins, or silos and can be used as a plug or choke detector in chutes, conveyors and elevator legs.

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Overheated bearings are one of the main risk factors for dust explosions in bucket elevators and need to be closely monitored.
4B offers a range of Atex, CSA and IECEx certified bearing temperature sensors and compatible monitoring systems.

View our full Electronics Catalogue here.

Bearing Temperature Sensors

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4B's line of speed switches includes: proximity, inductive, zero speed, stop motion and rotary encoders to monitor dangerous belt slip, underspeed or stop conditions on conveyors, bucket elevators and any other shaft driven machinery. Our non-contacting sensors can be used to detect screw conveyor flights, elevator bucket bolts and other moving ferrous targets. Speed switches can be connected to a PLC or to one of 4B’s hazard monitoring systems to provide alarm and/or shutdown of your machinery when dangerous conditions are detected.

View our full Electronics Catalogue here.

Speed Switches

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Monitoring

IE-Node

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IE-Node

The Industrial Ethernet Node (IE-NODE) is a remote monitoring interface designed to provide sensor data to PLC’s or other automation and control systems.

Both units can be expanded to 16 sensor inputs with the installation of optional expansion boards.

The IE-NODE operates by reading its sensor inputs and sending processed data when requested by another system (e.g. PLC). The units are equipped with an RJ45 Ethernet socket and supports PROFINET, EtherNet/IP and Modbus TCP/IP protocols for easy integration with Siemens, Allen-Bradley Rockwell, Modicon and other PLC’s or automation devices.

The IE-NODE’s network configurator software provides a visual view of all devices on the network. It allows for easy identification of each unit on the network and allows for network settings to be changed as needed.

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B400 Elite Beltswitch

The B400 Elite Beltswitch belt misalignment monitor uses 4B Touchswitch sensors to monitor belt alignment in bucket elevators and conveyors. Each control unit incorporates two independent monitoring circuits for early detection of belt misalignment on one or two bucket elevators / conveyors. The 4B Touchswitch is an electro-mechanical limit switch with no moving parts. When a belt misaligns or a pulley moves over and contacts the sensor, the built in solid-state electronic circuitry detects the lateral force of the belt or pulley and activates a voltage free relay contact. Status LEDs on the control unit indicate the alignment condition of the belt, while internal relay contacts provide alarm and automatic shutdown of the elevator when hazardous misalignment conditions are detected.

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Watchdog™ Super Elite (WDC4)

Watchdog Super Elite hazard monitor (WDC4)

Watchdog™ Super Elite (WDC4)

The Watchdog Super Elite (WDC4) is easy to install and simple to set-up. The system processes signals from sensors for belt misalignment, belt speed & slip, continuous bearing temperature, pulley misalignment and plug conditions for bucket elevators or belt conveyors. When an alarm is detected it will sound an alarm and provide shutdown control of the elevator/conveyor and feeding system.

A 3.5” LCD screen displays the entire system status at a glance. Password protected controller settings can be set up either directly on the LCD screen, or by a PC application and transferred to the WDC4 via an SD card.
The Watchdog Super Elite can be connected directly to a PLC using the Modbus TCP/IP protocol, or integrated into HazardMon.com®. This secure cloud based solution provides live system status, graphs and historical data that is viewable on any web-enabled device (smart phone, tablet, desktop PC).

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T500 Elite Hotbus™

The T500 Elite Hotbus™ is a serial communications system designed to monitor up to 256 sensors for combined belt alignment, belt speed, continuous bearing temperature, pulley alignment, level indication (bin / silo) and plug conditions on bucket elevators and conveyors. With automatic machine shutdown capability and PLC / PC compatibility, this advanced microprocessor based system offers low cost installation, versatility and easy system expansion. Logging and trending software is also available for historic data analysis and preventative or predictive machine maintenance.

HazardMon.com® is a secure cloud based hazard monitoring solution providing status notifications and data logging for bucket elevators and conveyors. Live system status, graphs and historical data can be viewed on any web-enabled device (smartphone, tablet PC, desktop or laptop computer). Emails can be sent to notify users whenever a change in the system's health is detected. An automated maintenance feature allows site operators to verify that all sensors on the system are operational and working correctly.

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