Safety and Production Issues? Signs You Need a Conveyor Belt Speed Sensor

Conveyor Belt Speed Sensor on a production line

Barnes Concrete Co., a manufacturer of ready-mix concrete, handles tons of bulk material a day. They have 12 mixers, with feeders loading up to 250 tons of gravel an hour.

Any equipment malfunction would lead to an avalanche of bulk material which could injure workers and delay production for days. Plant supervisor Joe Kruzewski estimates it would take three people at least three hours to clear one ton. “It would be a train wreck [to be] buried with that amount of gravel.”

Fortunately, the concrete company never had an accident. Twenty years ago, they installed a conveyor belt speed sensor: DAZIC zero speed switch. It would signal whenever there was any abnormal change in the conveyor’s speed, so the team could quickly shut down the process before a pile-up occurred.

How does a conveyor belt speed sensor work?

A conveyor belt speed sensor measures the speed of a conveyor belt by detecting the rotation of one of the belt’s rollers or pulleys.

It is mounted on the shaft of the roller or pulley and generates an electrical signal as the shaft rotates. Then, it converts the signals into a speed measurement, typically expressed in revolutions per minute (RPM) or meters per second.

The DAZIC zero speed switch takes it a step further. Aside from measuring the speed, it sets off an alarm when RPM falls out of normal parameters.

For companies like Barnes Concrete Co., the DAZIC is a simple device that saves them a ton of problems. “It would be a nightmare if the DAZIC didn’t shut the conveyor belt down. I don’t even want to think about it,” Kruzewski said.

What are the benefits of a conveyor belt speed sensor?

Any manufacturing company can benefit from a DAZIC zero speed switch. It can:

  • Prevent accidents like material spills and pile-ups
  • Prevent bottlenecks by ensuring consistent equipment speed for synchronized processes
  • Allow preventive maintenance by identifying potential equipment issues before they become serious problems

Signs you need a conveyor belt speed sensor

If you’re experiencing these issues in your plant operations, consider installing a DAZIC zero speed switch on your conveyors or any other equipment with a rotating shaft (bucket elevators, drive motors, saw blades, etc.)

  • Frequent machine breakdowns. Changes in speed are often the first sign of other mechanical problems. A DAZIC zero-speed switch can detect these slowdowns in real-time so you can take corrective action, protecting your equipment from further damage.
  • Safety concerns. Material pile-ups and spills are not the only safety issue when equipment runs at an inappropriate speed. It can lead to overheating, vibration, or other malfunctions which can cause accidents or even fires.
  • Inefficient production line. When a machine slows down or stops unexpectedly, it can cause disruptions in the production line, affecting the overall workflow. A zero-speed switch enables you to fix the issue quickly to prevent bottlenecks and downtime.

Learn more about DAZIC

A DAZIC zero-speed switch can protect your equipment, improve productivity, and ensure a safer work environment. Contact us to find out more about DAZIC and how it can work in your process.

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