INTERNATIONAL
Loopless Rip Detection: Proven Conveyor Protection in Mining
On May 15th, REMA TIP TOP’s Loopless Rip Detection System (LRDS) successfully detected a longitudinal rip in a steel cord belt at an Australian site. The 4 km-long belt was automatically stopped by the PLC, limiting the ripped length to just 8 metres and preventing significant unplanned downtime. Saving the customer hundreds of thousands of dollars. This event reaffirms the LRDS’s proven performance across both fabric and steel cord
belts.
Challenge
Traditional rip detection methods require embedded loops, wires, or inserts. These are expensive, harder to install, and often prone to failure. There was a need for a low-maintenance, loopless solution that could detect longitudinal rips early—before major damage occurs.
Solution
REMA TIP TOP installed the LRDS across multiple sites since mid-2024. Unlike traditional systems, the LRDS:
- Requires no loops, inserts, or embedded wires
- Uses motor current, voltage, ambient temperature, and fixed conveyor parameters
- Calculates a live ‘rip score’ multiple times per second
- Sends a signal to the PLC when the score exceeds a threshold, stopping the belt instantly
The system is cost-competitive, low maintenance, and effective for both fabric and steel cord belts.
Key Metrics
- 20+ LRDS units installed in Australia since mid-2024
- Successful rip detections across textile and steel cord applications
- Damage is limited to 8m in the most recent steel cord event
- Zero downtime injuries
- Significant cost savings for the customer
Outcome
The LRDS delivers on its promise of high-confidence, real-time protection without complex belt modifications. It offers Australian mining operations a scalable, proven alternative to traditional rip detection technology, helping reduce risk and extend belt life.
This case highlights how LRDS delivers real, measurable benefits for mining operators.
Find out more about the technology: Loopless Rip Detection