Smart-Idler is an industrial IoT based condition monitoring system that embeds wireless, intelligent sensor modules within the roller components of conveyor belts, where sensors harvest their energy from the rotation of the roller they are embedded within. Through temperature, rotation and vibration monitoring, roller failure can be quickly identified, avoiding costly production downtime.
Conveyor belt failure due to idler roller damage can affect both upstream and downstream processes and is usually considered a cost of doing business. But that cost can be very high – in excess of $US1 million an hour.
There is no simple solution, and manual inspections of idlers are:
risky, as employees need to walk close to the conveyor
irregular due to staff availability
laborious and time consuming, and people tend to slack off while inspecting about 3 rollers per meter for thousands of meters.
As a leading Industrial Internet of Things (I0T) technology company, Vayeron provides solutions to industrial process productivity challenges that anchor physical equipment to the digital world.
Smart-Idler is the company’s answer to the problem of failed and failing idlers that cause conveyor belt damage, overheating temperatures and noise pollution.
It’s an industrial IoT based condition monitoring system that embeds intelligent sensor modules within the roller components. The sensors are maintenance and battery free, harvesting their energy from the rotation of the roller in which they are embedded. Their monitoring capability is holistic. Through temperature, rotation and vibration monitoring, they can comprehensively monitor for all leading physical parameters that indicate eventual roller failure.
The technology gives industrial companies the ability to monitor idlers autonomously, providing online 24/7 predictive maintenance insight, preemptive failure detection, and increased safety while reducing downtime.
The system is completely wireless. The data from the sensors is networked to a cloud or on-premises server, control system or third-party software for machine learning and Artificial Intelligence overlay.
This wireless communication allows end users to save money and time monitoring and replacing idlers during unscheduled maintenance.
Smart rollers are like-for-like replacements for ordinary rollers in high capacity, time-critical conveyors found at mines, ports and process plants globally. Verayon is also working with roller manufacturers to integrate the technology in their products at the time of manufacture.
Vayeron aims to become a globally renowned technology innovator through the development of useful technologies, such as Smart-Idler, that allow industries to maximise efficiencies and reduce operational costs.
The company conceptualises, manufactures, and sells wireless monitoring technologies which are innovative and unique in their design and capability. Its objective is to make products that are easy to deploy, operate and maintain whilst achieving a high return on investment for the end-user.
Operating from Mackay, Queensland, Vayeron uses a network of partners and representatives to establish a "whole-of-product" offering. This means worldwide customers have access to a full product experience enriched by sales and after-sales support, and product ecosystem value.
