How SAM4 helps prevent belt conveyor failures

Table of contents

Unplanned downtime can severely disrupt operations and result in high repair costs, especially when it involves critical equipment like belt conveyors. SAM4 is a predictive maintenance tool designed to detect developing faults in belt conveyors, giving you the chance to fix them before they become serious problems. In this blog, you’ll learn how SAM4 can reduce downtime, extend equipment life, and ensure smoother operations.

We’ll explore how SAM4 works, the types of faults it detects, and real-world examples of its effectiveness.

How SAM4 works

Belt conveyors are widely used in many industries, but over time, mechanical and electrical issues are bound to arise. SAM4 uses Motor Current Signature Analysis (MCSA) and voltage measurements to monitor conveyor systems and detect faults early.

Motor current signature analysis (MCSA)

MCSA analyzes the electrical current drawn by a motor, which contains valuable information about the health of the equipment. SAM4 monitors this current to spot any changes that signal an issue is developing.

SAM4 stands out by adding voltage measurements to the standard MCSA technique. This allows it to filter out distortions in the power supply, improving the accuracy of fault detection. The system also relies on AI-driven analysis that learns from the equipment’s normal operation. This means it can catch even small anomalies that traditional methods might miss. When an issue starts to develop, SAM4 sends real-time alerts, allowing you to address the problem before it leads to equipment failure.

Scherm­afbeelding 2024 10 30 om 11. 24. 27

Traffic light alerts

SAM4 uses a traffic light system to show the status of your conveyor:

  • Green: Everything is operating normally, with no need for action.
  • Yellow: There’s a minor issue that doesn’t require immediate attention but should be monitored.
  • Orange: A more significant problem has been detected, and the equipment should be inspected soon.
  • Red: Immediate action is necessary to prevent failure.

This simple alert system helps you focus on critical maintenance tasks and avoid unnecessary inspections.

What SAM4 detects

SAM4 can detect a range of mechanical and electrical issues. Some common examples include mechanical unbalance, bearing faults, and belt misalignment.

Mechanical unbalance

Mechanical unbalance occurs when rotating parts such as pulleys, drive shafts, or motor rotors are out of alignment. This creates stress on the conveyor, which can eventually lead to system failure. SAM4 monitors the motor’s rotational frequency and identifies when energy spikes indicate an unbalance.

In one instance, SAM4 detected a mechanical unbalance caused by a loose gearmotor and a contaminated brake. After receiving the alert, the client inspected the conveyor, tightened the motor, and cleaned the brake. These simple adjustments resolved the issue​! 

Bearing problems

Bearings play a crucial role in ensuring that conveyors operate smoothly. However, over time, they can wear out or become damaged. SAM4 monitors bearing-related frequencies and detects changes that indicate a developing issue.

For example, SAM4 identified increasing energy at bearing frequencies in a conveyor. The client’s inspection revealed damage in both the drive-end and non-drive-end bearings. By replacing the damaged bearings, they avoided a shutdown and restored the conveyor to full working order​(SAM4_for_belt_conveyors).

Real-world examples of SAM4 in action

SAM4’s ability to detect issues early has proven effective in real-world scenarios.

Case study 1: worn components

SAM4 detected a rise in energy at the motor’s rotational frequency, suggesting a developing issue. The client chose to monitor the situation instead of taking immediate action. After four weeks, the energy levels spiked, and SAM4 upgraded the alert to red. Upon inspection, the client found that the drive pulley, drive shaft, and belt were all worn. Replacing these components brought the system back to normal operation​(SAM4_for_belt_conveyors).

Case study 2: belt misalignment

In another case, SAM4 detected a gradual rise in energy at the interharmonics of the current spectrum. This led to the identification of a misaligned belt. After realigning the belt, the conveyor returned to healthier energy levels. However, further monitoring revealed that the roller was also faulty. Replacing the roller fully resolved the issue, bringing the system back to optimal performance​.

Reduce downtime with SAM4

SAM4 helps you stay ahead of potential issues with your belt conveyors. By continuously monitoring the mechanical and electrical data from your motor, SAM4 ensures that you can detect and address faults early, well before they result in major problems. This proactive approach means less downtime, fewer costly repairs, and a longer lifespan for your equipment.

With SAM4, you can plan maintenance around your schedule, address problems before they escalate, and keep your operations running smoothly.

Book a demo

Get professional advice on how to monitor hard-to-reach assets from the motor control cabinet.

Talk to an expert

Monitor your hard-to-reach assets from the motor control cabinet

30 mins, no obligation

Experience our product firsthand

ABB_logo
Nobian-Logo
yorkshire-water-logo-white
thames-water-logo (1)
Schneider_Electric_logo