A PLC Solution for Minimizing Downtime from an Actual Belt Conveyer Problem Occurring on a Gold Mineral Production Line

Abstract

One of the best methods for transporting materials from one place to another is a smart belt conveyer system a with Programable Logic Controller (PLC). Since a PLC helps belt conveyers avoid slipping, overloading, and malfunctioning during operation time, maintenance costs and downtime losses are reduced. In this work, the existing Ma’aden-Al Duwaihi belt conveyer system and the related issues have been examined. Then, the operations logic has been simulated and modified by adding programable logic controller-PLC. After that, the proposed solution has been implemented on laboratory prototype. Practically, one unit of the PLC should be added to the system. However, the conveyer system eventually becomes smarter. The main contribution of the presented work is updating the belt conveyer system, which previously has been only relay-dependent on a PLC’s fully automated materials handling system. Both system design and implementation are discussed herein. Investment in PLC implementation has proven to be beneficial over the long term. A PLC automates materials handling and sorting, significantly reduces downtime, and makes the implementation of a more advanced optimal algorithm possible.