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WEBINAR: Non-Contact Conveyor Solutions
for Volume Flow Measurement and Condition Monitoring - Bulkscan® LMS511
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www.sick.com/cement
1
Non-Contact Conveyor Solutions – Bulkscan LMS511 | Felix Bartknecht, Helen Zimmermann, Karsten Twisselmann | SICK AG

Felix Bartknecht
Helen Zimmermann
Karsten Twisselmann
SICK AG
Webinar:
Non-Contact Conveyor Solutions
for Volume Flow Measurement and Condition Monitoring - Bulkscan® LMS511

Non-Contact Conveyor Solutions – Bulkscan LMS511 | Felix Bartknecht, Helen Zimmermann, Karsten Twisselmann | SICK AG 3
Agenda
1. Who we are
2. SICK AG
3. Conveyor operation
4. Sensor Applications
- Volume Flow Monitoring
5. Condition Monitoring
6. Summary
7. Q & A

Who we are
Daniel PEREIRA
Market Product Manager
Analyzers & Flow
BENELUX
Mobile: + 32 470 205 778
E-Mail: daniel.pereira@sick.be

SICK AG
SICK – worldwide one of
the leading manufacturers of
sensors and sensor solutions
for industrial applications

› Tasks of conveyors in industrial applications:
− Transportation of heavy and bulky materials & fuels over short and very long distances
− Maintain continuous flow for conversion processes
− Accumulation & sorting of material
− Elevation of materials
− Increase plant efficiency (no mobile machines needed)
› Typically used in:
− Cement, lime, power, waste & recycling, mining, metal & steel, harbours, consumer goods etc.
Conveyor operation

Conveyor operation
› Transportation of:
− Raw material & additives
− Coal, petcoke & alternative fuels
− Clinker
− Cement
− Cement bags
− Pallets
1
1
1
1 1
1
2
3
3
3
4
5
4
1 Belt conveyors
Vibrating conveyors
Bucket conveyors
Pneumatic conveyors
Roller conveyors
2
3
4
5
2
3

Conveyor operation
› Problems using belt scales for mass flow measurement
− Reading affected by moisture content
− Space requirements & positioning (e.g. inclines)
− Jamming possible
− Time consuming calibration procedure
− Mechanical/moving parts (lubrication needed)
− Belt tension too high or too low
− Maintenance intensive
− Inaccurate loading affects measurement
− Resonance effects
− Measurement dependent on conveyor belt design
− Insufficient accuracy (>>5 %), repeatability & linearity (esp. B2B)

Sensor Applications - Volume Flow Monitoring
› Non-contact volume flow measurement
− Infrared Class 1 Laser Scanner (safe under all conditions)
− For all open conveyor types
− Real time volume flow (13 ms)
− Density & mass flow calculator; 𝜌= 𝑚 ̇/𝑉 ̇
− High operating range (0.5…20m)
− Wide aperture angle (190°)
− 5 echo-pulse technology
Bulkscan LMS511

Bulkscan
V(n)
V(n+1)
V: Volume of a bulk good
slice at the time x
Belt velocity
V(n+2)
V(n+3)
V(n+4)
measurement
area
Measured values
V(n+x)
v

− Control of conveyor loading and speed
− Overfill protection
− Reduction in maintenance costs and downtime
− Measurement of volume (mass) flow, conveyor speed,
roller movement control and positioning
− Increase in production efficiency (output , energy )
− Increase in material output and energy saving
− Control the dosing process
− Increase in operational plant availability
− Acces to Bulkscan from above  no need to stop the
conveyour if the Bulkscan fails
Bulkscan LMS511

− Light source: Infrared (905 nm)
− Max. scan frequenzy: 35 Hz, 50 Hz, 75 Hz
− Scanangle: 190°
− Angle resolution: 0,5°
− Response time: 13 ms, 20 ms, 30 ms
− Laser class: 1, IEC 60825-1 (2007-6),
eye-safe
− Heating system yes
− Ambient temperature: -30 ... +50°C
− Degree of protection: IP67 Bulkscan LMS511

› Non-contact volume flow measurement – Bulkscan LMS511
− High operating range (0.5…20m)
− Wide aperture angle (190°)
0.5 – 20m
190°

− 5 echo-pulse technology

Bulk height
Center of gravity
Bulk edge & Conveyor edge
▸ Increased belt life (loading alert)
▸ Minimum maintenance
▸ Non contact measurement
▸ Unaffected by environment
▸ High resolution

− Center of Gravity Calculator

− Bulk Edge Calculator
C

− Belt Edge Calculator

− Contamination Measurement
• Information / Warning output
• Diagnostics on the device
− Bulk Height Measurement
• Information / Warning output
• Diagnostics on the device
Perpendicular point strategy Highest point strategy

− Signals
Ethernet TCP/IP
6 digital outputs
4 digital inputs
IO: Analog
4 x Outputs 4…20mA
4 x Inputs 4…20mA
Separate power supply
BAM100
Profinet, Ethernet/IP
(function blocks for Siemens PLCs,
Rockwell PLCs, Beckhoff PLCs)
Others if required ?

Crusher monitoring Raw material monitoring Coal / bulk fuel monitoring Alternative fuel monitoring
Clinker belt monitoring
and many
more…!
Stock pile measurement Truck / train filling

− Installation on clinker cooler belt
According to customer:
▸ Measuring accuracy of ± 2 %
▸ Device is working since 2 years
without any maintenance demand

− Installation on raw material & coal & secondary raw material belt

− Installation on metal recycling belt

− And many more….

− Sequence of bucket conveyor calibration
Run empty conveyor system
(without bulk material)
Calculate negative offset
of compensation function
Manually modify compensation function
(equation)
Teach-in reference contour
while conveyor system is standing still

− Mounting & Covers
Protection hood Weather hood

Sensor Applications – Tire/Rim Detection
› Non-contact 2D LiDAR Sensor + Encoder
− Tire / rim detection system for separation unit
− Sorting out of broken tires and rims
C
+

Sensor Applications – Tire/Rim Detection
› Non-contact 2D LiDAR Sensor + Encoder
− Tire / rim detection system for separation unit  Guarantee of continuous fuel flow
D D
D

Sensor Applications – Belt Drift & Staple Wear Detection
› Belt drift detection
− Suboptimal conveyor loading
− Material can be lost
− Increased belt wear
− Belt can derail
Laser distance sensors detect belt drift
Operator is alarmed
› Wear detection on conveyor staples
− Clamps used to connect belt ends
− high tension levels & signs of wear
− Belt can rip apart
Inductive sensor & 2D vision cameras check
belt clamps without stopping the belt
Operator is alarmed

Sensor Applications – Staple Wear Detection
› Wear detection on conveyor staples  predictive maintenance
Camera mounted to capture belt staple Belt Splice captured (belt running at 6 m/s)
Inductive sensor triggering from staples

Sensor Applications – Early Fire Detection
› Outlook: Early fire detection / prevention of silo fires
− Stop of conveyor belt in case temperature exceeds limit value
Temperature
Measurement
(e.g. IR camera)
Volume flow
Measurement
(by Bulkscan LMS511)

Condition Monitoring
› SICK Monitoring Box – Making use of Vital Sensor Data
› Real-time condition monitoring and analysis
by visualizing data in a browser based dashbaord
› Reduces unplanned maintenance work,
machine breakdowns and downtimes
› Extends the service life of critical components
› Ease-of-use through predefined Monitoring
Apps facilitate the connection of sensors
1
2
Collection and preprocessing of
sensor vital data
Smart Sensors delivering
Smart Data
3 Visualization of vital data and
conditions

Condition Monitoring
› SICK Monitoring Box – Making use of Vital Sensor Data
Trend Data Historic Data Alarms Rules
Asset Browser
Event Logbook
Status of
critical
parameters
Statistics
Responsive
Design

Summary
› More & more cement companies digitize their value chain (quarry  bagging)
› Sensor data help to:
− Create better productivity C
− Increase resource & energy efficiency C
− Reduce equipment downtime C
− Increase plant safety C
− Reduce emissions C
− Optimize production flexibility C
− Reduce production costs C
− Increase customer satisfaction C
− Enhance plant safety & security C
− Develop new business models C

Summary
SICK Cement Website: https://www.sick.com/cement
SICK Cement Industry Guide: Link
SICK Cement Video: https://www.youtube.com/watch?v=CniL84OtnEI

Q&A
www.sick.com/cement
www.sick.com/conveyor
Many Thanks for Your Attention.

ERWIN SICK
Company foundation in 1946
Next Webinar: Monday, June 22 2020 10:00 & 16:00 (CET)
Topic: 3D Cameras for Collision Awareness and Driver
Assistance Solutions for the Cement Industry
Presenter: Patrick Zessin, Product Manager
Muhammet Albayrak, Applications Engineer
3D Compact Systems, SICK AG

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