CPS Vayeron Smart-Idler - Case Study

8/10/2019 CPS Vayeron Smart-Idler - Case Study

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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!

Documents

CPS Vayeron Smart-Idler - Case Study