In an environment where data-driven decisions have taken root, particularly in mining and industrial operations, having access to highly detailed, real-time data has always been a priority – but traditionally this has always come with the significant cost of installing and maintaining an array of complex instruments.
This conventional approach, though effective, was generally cumbersome and resource-intensive. In a departure from this traditional approach, Tru-Trac has introduced an intelligent belt scale that eliminates the need for an intricate network of instruments and replaces this with a more effective, single, unified system.
According to Tinus Ludik, sales manager – Bulk Materials Handling Division at Tru-Trac, the system, which made its grand international debut at bauma 2025 (April 7-13) in Munich, is “the pinnacle of advanced technological innovation, offering unparalleled accuracy and efficiency.”
The belt scale integrates with yet another Tru-Trac innovation, the Rip Prevent+ system, which made its local debut at Electra Mining Africa 2024, where it also won the Innovation Award, highlighting the game-changing nature of this technology.
The Tru-Trac Rip Prevent+ system allows mines and other bulk material handling operations to optimise their conveyor lines’ performance by preventing costly interruptions due to rip events. Using a data-driven model and artificial intelligence (AI), the Tru-Trac Rip Prevent+ system can detect anomalies or rip events on any conveyor belt type, including steel cord, pipe and fabric belts.
“Integrating the proven capabilities of the Tru-Trac Rip Prevent+ system, we have created a groundbreaking intelligent belt scale that is technologically advanced, yet still easy to use, while offering an immense amount of data that was never previously available from any of the available belt scales in the market,” says Ludik.
The belt scale and Rip Prevent+ combination is connected to the clients’ internal networks, allowing them to monitor all the parameters on a Tru-Trac designed dashboard installed in the control room, and is available via ethernet connection. While the system can be made available online, most customers, says Ludik, prefer to keep all their critical information within their organisation, for security reasons.
Real-time load cell monitoring
At the heart of the system, says Ludik, is the real-time load cell monitoring feature, designed to ensure that millivolt (mV) signals remain within their optimal range and balance. Load cell health is continuously monitored, and if any discrepancies or deviations from the norm are detected, the system sends proactive warnings. The early detection allows for timely interventions, significantly reducing the risk associated with inaccurate or inconsistent readings.
This preventive monitoring is essential to ensure repeatability and accuracy of the scale. By providing insights into load cell performance, the system empowers customers to track and maintain their equipment, enhancing overall operational reliability and longevity.
The new smart junction box, which averages out the values from the load cells and speed sensor, allows for monitoring of individual cell signals. To function properly, the belt scale’s load cells must be balanced within 0,5 mV of each other, and having individual load cell signals now allows Tru-Trac to monitor those stringent parameters. Having balanced load cells enhances repeatability of results, which in turn increases accuracy.
“From a productivity point of view, the biggest improvement comes from the high level of accuracy and repeatability because we are now able to monitor a wide range of parameters that we were never able to monitor in the past. Previously, one had to physically measure the millivolts on each load cell with a multimeter. Now all this information is accessible remotely, in real-time and continuously monitored against historic patterns” says Ludik.
AI-driven calibration
One of the most remarkable features of Tru-Trac’s intelligent belt scale is its ability to automatically detect and correct any inaccuracies without the need for manual calibrations. Through the use of advanced AI algorithms, the system continuously analyses and cross checks the belt scale readings against mass flow measurements to identify any deviations in measurement accuracy. If any anomaly is detected, the system is capable of automatically initiating early-stage corrective measures such as remotely recalibrating the belt scale.
This feature greatly improves reliability and reduces maintenance, as it eliminates the need for personnel to conduct routine calibration or perform manual adjustment corrections. With the system working autonomously, human intervention is only necessary when critical issues arise, thereby reducing human error and operational disruptions.
“The main aim is to increase accuracy and repeatability,” explains Ludik. “Once the system senses that there is deviation, it will automatically calibrate itself without human intervention. Some of the alerts triggered when a deviation occurs include inaccuracy alerts, belt misalignment alerts, imbalanced load cell alerts, possible future load cell failures and belt scale under- or over-reading.”
Uneven Load and Belt alignment monitoring
The intelligent Tru-Trac intelligent belt scale system goes beyond simple weighing to monitoring of the health of the entire conveyor system, thus ensuring material flow consistency. Through continuous load cell mV readings, it assesses the alignment of the conveyor belt, detecting potential misalignment caused by off-centre material distribution. This real-time monitoring feature that tracks individual load cells and detects deviations while measuring weight distribution per load cell ensures even material loading.
This helps prevent costly damage to the belt and related components, reducing maintenance costs and prolonging the life of the customer’s equipment.
Productivity metrics
In addition, the Tru-Trac intelligent belt scale system does not only focus on immediate operational accuracy, but it also provides insightful long-term data that helps with decision-making and productivity forecasting.
By continuously monitoring key performance indicators (KPIs), it offers customers real-time insights into their plant’s efficiency. This allows for more accurate production forecasts and a clear understanding of the overall productivity percentage, which is directly correlated to profitability.
“By having access to such detailed, actionable data, plant managers can make informed decisions that optimise operations, improve throughput and ultimately drive better bottom-line results,” says Ludik.
Real-time anomaly detection
In addition, the system incorporates advanced anomaly detection capabilities that continuously monitor and analyse all operational parameters of the conveyor in real time. Should any irregularities or discrepancies arise, the system is capable of flagging them immediately for further investigation, ensuring that potential issues are addressed before they develop into more significant challenges. This real-time oversight fosters an environment of constant optimisation and operational excellence.
“The system helps customers manage their preventative maintenance regimes better because they have a continual understanding of what is happening with their conveyor belts. This offers numerous benefits, including reduced downtime, increased conveyor belt lifespan, improved safety, enhanced efficiency and significant cost savings, by preventing costly repairs and extending belt lifespans,” says Ludik.
Target industries and integration
The Tru-Trac intelligent belt scale, says Ludik, can integrate with existing Tru-Trac belt scale solutions. The system is good news for all industries that run conveyor belts and have accuracy, repeatability and production at the top of their priorities. Well before the official launch at bauma, several potential customers had already expressed interest in the system, and installations are imminent.
“In terms of the early adopters, I think the system will appeal to high-value commodity operations such as platinum, gold and copper mines, amongst others, where the plants run at millions of rands per hour and any form of inaccuracy and downtime are out of the question. Having such an advanced solution that ushers in a new era in belt weighing is critical for their operations,” concludes Ludik.
