Solution architectures for CONVEYANCE

CONVEYANCE

Solution architectures for

Solution architecture for mining conveyors Our integrated solution increases OEE for conveyors in mining

Integrated approach for motor control and automation that enables design

productivity, safety, visualization and predictive analytics

Drive systems with simplified internal design for maximum uptime

Integrated safety solution that reduces unnecessary stops and delivers

enhanced diagnostics

Drive systems that include enhanced characteristics for conveyor applications,

(such as regenerative for downhill and master follower for torque coordination)

Transfer control solutions allow better traceability of materials, management of multiple ores (without mixing them) and

gap control for chute switchover

Performance loss• Reduced throughput • Reduced speed• Small stops

Quality loss• Bad quality ore

Unified solution integrating automation

with dedicated conveyor functions, motor control and distributed safety in

a single backbone

Downtime losses• Downtime • Setup and adjustments • Idle time

Availability

Performance

Quality

A

A

P

P

Q

Q OEE

2Solution architectures PG 2

Simplified architecturesPG 3

PowerFlex LV & MV Drives for conveyorsPG 5

Medium voltage drivesPG 6

Premier integrationPG 7

Conveyor safetyPG 8

Transfer controlPG 9

Simplified architectureREMOTE MONITORING

SINGLE MODE FIBER

MINING PROCESS CONTROL SOLUTION

SAFE TORQUE

DISTRIBUTED SAFETY & I/O

HEAD END

CONVEYOR

TAIL END

SENSORS (temperature, speed, metal

detector, misalignment, rip detection)

DYNAMIC WEIGHING

CROSS BELT ANALYZER

SAFETY DEVICES: PULL CORD






Conveyor safetyPG 8


REMOTE MONITORING

SINGLE MODE FIBER

MINING PROCESS CONTROL SOLUTION

SAFE TORQUE

DISTRIBUTED SAFETY & I/O

HEAD END

CONVEYOR

TAIL END

SENSORS (temperature, speed, metal

detector, misalignment, rip detection)

DYNAMIC WEIGHING

CROSS BELT ANALYZER

SAFETY DEVICES: PULL CORD

FactoryTalk® InnovationSuite:Remotely monitor assets, predict equipment failure, and identify improvement opportunities.

Converged Plantwide Ethernet Architectures: Tested and validated reference architectures co-developed by Rockwell Automation and Cisco enable IT/OT integration, quality performance and security at every level.

PowerFlex® Low Voltage and Medium Voltage Drives• Includes enhanced

characteristics that address conveyor applications (regenerative for downhill, master follower for torque coordination) .

• Advanced diagnostics.• Premier Integration with

control systems.

Enhanced Safety Solutions for Conveyors:Reduce the complexity and cost of your safety solution with an integrated safety solution for conveyors.

Dynamix™ Integrated Condition Monitoring System Dynamically monitor sensor information (vibration, speed, etc.) to identify potential equipment issues before failure occurs. Offers configuration in any Allen Bradley® ControlLogix® controller.

FactoryTalk® InnovationSuite Use augmented reality technologies to gain real-time equipment operating and performance information, as well as enable collaboration for equipment maintenance.

FactoryTalk® Analytics™ LogixAI™ Use an embedded artificial intelligence

module to find optimizations at the operation level, with no data

scientist required.

Premier Integration between Power and Control:

Save engineering time and reduce operational costs with better

integration between process, motor control and electrical distribution

applications (across design, operations and maintenance).

Process Control for Mining:• Pre-engineered content for mining control,

monitoring, and reporting that’s built on our standard PlantPAx® Distributed Control System. Includes mining-specific applications such as dedicated control strategies for conveyors.

• Simplify programming, configuration and maintenance of controllers and field devices with unified tools.

• Premier Integration with drives.






Conveyor safetyPG 8


SOLUTION AT A GLANCE

PowerFlex LV & MV Drives for conveyors PowerFlex® drives improve power quality, equipment performance, uptime, and safety

Reduce downtime caused by mechanical issues by automatically identifying and suppressing harmful resonance and vibration conditions using adaptive tuning, enabled by TotalFORCE® Technology.

Continuously monitor operation and remaining life of components based on actual operating conditions. Avoid unexpected downtime caused by component failure with predictive maintenance capabilities, enabled in the PF755T by TotalFORCE® Technology (LV).

Leverage motor-friendly waveforms to retrofit existing motors with existing motor cables on medium voltage drives — no need for inverter duty motors.

Reduce MTBF (mean time between failures) and go up to 30 km motor cable

with advanced medium voltage technology without output filtering.

Reduce overall system complexity as well as e-house cooling costs

with a transformeless solution: no isolation transformer needed

between the drive and power source for harmonics mitigation.

Gain higher reliability and maximum uptime with a modular design that has low component count and low electronics failure rate. Switch a cell from our drive solution in just a few minutes (compared to 1.5 hours for a conventional drive).

Precisely control speed and torque, with high-performance motor control enabled by TotalFORCE® Technology (LV). • Reduce conveyor wear and cut down on energy

consumption by implementing smooth acceleration and deceleration curves instead of the traditional trapezoidal motion profiles — no special programming needed.

• Control for disturbances by ‘throwing out’ isolated conveyor disturbances from drive system data and eliminating unnecessary output adjustments.

Protect personnel and assets while enabling increased application uptime by removing

rotational power to the motor without shutting off the drive

using Safe Torque Off Optional. Enable safer maintenance by keeping the system running at a desired low speed with Safe

Speed functionality.

Continuously monitor and adjust for normal conveyor mechanical wear to maintain production with load observer, enabled

by TotalFORCE® Technology.

Gain built-in harmonic mitigation, power factor correction, and energy regeneration capabilities (downhill

applications) with regenerative power supply technology.

Maintain conveyor operation when utility power goes out or dips with

SEMI F47 compliance.

Reduce engineering and commissioning costs with Premier Integration, which provides a

simplified integration experience when configuring drive operation and control

into the Logix environment. Includes design productivity, controller-based safety, Application

Code Manager, Automatic Device Configuration, mobility and visualization, and analytics.

Master follower configuration






Conveyor safetyPG 8


USE CASE

Medium voltage drives for conveyorsDeveloping a truckless system for the largest iron ore mine in the world

A leading global producer of iron ore wanted to reimagine material transport at their largest site, with a specific goal of eliminating the cost of maintaining a fleet of 100 off-highway trucks and purchasing the fuel the consumed.

To do this, they replaced fixed crushers and off-highway trucks with movable crushers and conveyor belts. A system comprised of shovels and movable crushers now extracts the iron ore and feeds about 30 kilometers of conveyor belts, which lead the product to the processing plant.

The company has already dramatically reduced the amount of waste created from old tires, filters and lubricants. They also project they’ll experience a 77% reduction in fuel consumption.

Reduced waste and 77% reduction in fuel consumption.






Conveyor safetyPG 8



Premier integration between power & control Unified approach for design productivity, safety, device replacement, visualization and predictive analytics

Accelerate project engineering with a suite of pre-engineered control and HMI objects, including faceplates designed for user roles (operator, maintenance).

Provide valuable operating data to the right person at the right time with access to predictive maintenance data from the control system.

View process and electrical control data in a common infrastructure.

Reduce startup delays by configuring your system prior to installation, and also configuring controller and motor control device I/O at the same time using Startup Wizards that step you through the entire process.

Reduce errors and simplify programming by using a

single software tool to configure all system devices.

Minimize unplanned downtime and optimize maintenance efforts with

continuous monitoring of drive system components.

Automatically assign the configuration of an original device (IP address

assignment, firmware supervisor, device configuration) to its replacement

to reduce downtime.

Reduce travel time and better prepare technicians to perform needed repairs with on-site access to real-time performance data, user manuals and drawings.






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Leverage a single high-performance controller for

both standard and safety control (optimized for faster

safety reaction time) with the GuardLogix® controllers.

Enhance safety with dual motor stop capabilities through hardwire or network stop options.

Protect personnel and assets while enabling increased application uptime by removing rotational power to the motor without shutting off the drive using Safe Torque Off Optional (for applications where the de-energized state is the safe state).

Reduce wiring costs and simplify design and install with ArmorBlock® Guard I/O™ modules, which are rated for IP67 and communicate via Ethernet/IP™.

Dramatically reduce the complexity, expense and troubleshooting needed to set up a wired system by leveraging a distributed/remote safety system based on CIP Safety™ over Ethernet/IP™.

Connect information from safety switches and traditional sensors located anywhere on the conveyor using CIP™ safety protocol over Ethernet/IP™.

Reduce installation cost, improve diagnostic ability, and reduce false stops with microprocessor based Lifeline™ 5 Cable Pull Switches.

SAFETY I/O

TENSION INDICATOR


Conveyor safety Enhanced safety solutions for conveyor applications/distributed E-stop application. Reduce the complexity and cost of your safety solution with an integrated safety solution for conveyors.






Conveyor safetyPG 8



Transfer control

GAP GAP

ORE 2 ORE 1ORE 1

TrackingUtilize the speed, belt length, feed points and reference weightometers to accurately model the loading and positioning of product on the conveyor system.Track distribution of product along conveyors to optimize the loading process and avoid overload.

Gap ControlManage loading gaps across the system. Automatically switch a chute without tripping the best when the clearance (gap) is present.

Manage Multiple ProductsHandle multiple products on the same conveyor by creating a controlled gap between the products to increase belt throughput and operating efficiency.

600.00

0.02

0.02

0.03

0.04MM_FDR-003 GAP HI GAP LO

7E-3

45 30 15 0

MILL FEED CONVEYOR 1 TRANSFER ELEMENT

GAP






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USE CASE

Transfer controlManage multiple products: PGM Mining

Before installing the Transfer Control Solution, PGM Mining had to empty the entire 2.4 km long conveyor system in order to load a different product. It took 27 minutes.

With the Transfer Control Solution installed, PGM Mining is now able to switch to a different product in just 3 minutes.

PGM Mining is now able to switch to a different product in just 3 minutes






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Connect with us.

Allen-Bradley, ArmorBlock Guard I/O, Expanding human possibility, FactoryTalk Analytics LogixAI, GuardLogix, Lifeline 5 Cable Pull Switches, PowerFlex drives, Rockwell Automation, and TotalFORCE Technologyare trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication MIN-SP010B-EN-P - October 2020Copyright © 2020 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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Solution architectures for CONVEYANCE