With a focus on improving the performance, and increasing the reliability, of operations, Tru-Trac Rollers, a conveyor belt solutions manufacturer and supplier of the Tru-Trac conveyor belt scales, offers accurate and reliable measurement of bulk materials.

Considering accurate measurement and precise weighing systems are essential in industries such as mining, at processing plants and for aggregate handling for optimising production and the management of inventory, Tru-Trac CEO Jonathan Rogoff says belt scales are critical components in supplying important data to clients in real time.

Consequently, Tru-Trac’s conveyor belt scales leverage advanced technology, such as high-precision load cells and innovative digitisation, through the company’s recently launched AccuTrac Integrator to provide repeatable accuracy, even in the most challenging applications.

Rogoff warns, however, that any changes in the conveying system can affect the accuracy of belt scales, whereby factors such as overloading, material spillage and changes in belt tension resulting from mechanical adjustments can create inaccuracies.

Calibrations must be done after any mechanical changes are made to the conveyor line to ensure the scale is reading accurately, he adds.

“It is important to ensure that belt scales are installed at the right locations and in the correct way, because without care and diligence around the installation, you will get less accurate readings,” says Rogoff.

In addition to providing accurate and reliable weighing and continuous monitoring, Tru-Trac belt scales are manufactured using durable materials to withstand harsh environments. With this in mind, the company offers corrosion protection for the scales in the form of powder coating and painting, as well as galvanising.

By using a free-floating design to accurately weigh material, Rogoff says Tru-Trac has gone “back to basics” in its design, as sometimes overengineering complicates the performance of belt scales and introduces margins for error.

To ensure that all scale components are aligned, Tru-Trac has redesigned the belt scale idler frames to provide a low flex frame that achieves low deflection, enabling the scale to remain accurate, even under high-load applications.

The company also has incorporated semi-automatic calibration weights to help facilitate safe and quick span calibration of the scales.

To achieve greater accuracy, Tru-Trac also offers calibration chains and automated roller chain systems for extreme high-precision applications.

Tru-Trac product engineering manager Jaco Botha notes that calibration chains and roller chain systems enable higher accuracy and repeatability, as they simulate the actual load on belt characteristics, behaviour and tension.

“By simulating the actual weight using a dynamic belt, you are calibrating in belt tension and belt thickness variations, thereby ensuring your calibration is more accurate,” he says.

System Calibration

Tru-Trac conveyor belt scales can be easily integrated with control systems, data logging infrastructure and automation, enabling seamless data collection and process control.

To ensure ease of use, Tru-Trac has redesigned its AccuTrac integrator to facilitate easier programming and calibration of its belt scales through its touchscreen interface, enabling clients to quickly perform their own zero and span calibrations.

The integrator offers intelligent weighing, converting analogue inputs into precise digitised production monitoring and control data.

Custom designed for belt scale applications, it provides real-time tracking, data interpretation and automated reports through Tru-Trac’s remote monitoring platform.

“Our philosophy around empowering the customer has already paid off. With on-site or in-house training, our customers are now able to do their own calibrations immediately without having to wait for and pay specialist technicians to come to site to assist,” says Rogoff.

The scale and integrator are compatible with new or existing conveyor setups, simplifying installation and enhancing overall efficiency.

Rogoff notes that the AccuTrac integrator offers a range of outputs and communication protocols. Ethernet, DeviceNet, Profinet, Profibus DP, Dual 4-20mA, 4 Potential-free relays, RS232 and RS485 are offered by the AccuTrac Integrator, enabling it to connect with almost any programmable logic controller system.

Further, Tru-Trac belt scales are also complemented by an optional remote monitoring system, which offers real-time data access.

This gives clients remote access to information such as tonnage data, feed rates, belt speeds, low tracking, production target analysis, data visualisation and equipment efficiency metrics.

The integrator also includes an alert customisation feature to alert clients when belts are running overloaded or empty.

“The RMS has proved to be a real game changer for our clients. Having easier and instant access to data provides our clients with metrics that can help them run their plants more profitably,” says Rogoff.

The company offers a full range of belt scales, from single idler belt scales with accuracy errors of less than 1% to dual, four and six idler fully floating belt scales, which achieve accuracy errors of less than 0.1%.

Given the success of its belt scales, the company aims to expand its offerings to reach its global customer base.

With trained installation technicians available throughout Africa, the company provides full support and backup onsite for its belt scale products.

“Tru-Trac aims to continue being a leader in the supply of solutions for the bulk materials handling industry. Through embracing the use of technology, we have been able to help our customers achieve optimisation and profitability on their conveying systems, while also reducing downtime.

“Owing to repeatable, reliable and accurate metrics, we are achieving incredible success with our new and improved belt scale offering,” concludes Rogoff.