New MAJOR Flex-Mat Sensor makes screening performance easier with no downtime
MAJOR, a global leading manufacturer of high-performance screening media, introduces the Flex-Mat Sensor, a valuable and easy to operate vibration data measurement tool users can utilize to review results and fine tune their screen machine without shutting down the equipment. The app-controlled vibration analysis sensor enables readings of screen box vibrations within seconds and generates a report that can be sent or reviewed. The simplicity of the system’s design ensures valuable and actionable data without the requirement for a plant shutdown to calibrate the sensor.
“Our focus is on making our customers more profitable and productive. This technology does that by putting a wealth of screen performance data into the palm of their hand,” said Peter Bauer, MAJOR R&D and innovation manager. “The simplicity of our system makes it extremely accessible and allows dealers and their customers to make educated decisions to improve performance and profits.”
The Flex-Mat Sensor enables users to measure and — almost immediately — view vibration data. The operator connects the single sensor to the Flex-Mat Sensor app on their phone before placing the sensor on one corner of the machine. The user will continue to move the sensor to each corner of the machine until finished. Once the measurement process is completed, the information will be delivered to the phone in the time it takes to climb down from the machine.
Alternative systems may not provide the data until the following day. Machine information is stored locally for ease of use and viewing in areas with cellular limitations. Once signal is available, the information uploads to MAJOR’s cloud service where it is viewable from a web browser. Historical equipment performance data is also viewable through the cloud.
The sensor measures g-force, stroke, rpm and orbit, including lateral movement — a measurement not offered by many vibration analysis systems. Producers can use the data to monitor and fine tune screen box performance as well as make parameter decisions with minimal guesswork. For example, it’s difficult to tell just by looking at it whether a screen that’s supposed to be operating at 800 rpm is operating at 900 rpm because the difference in vibration could be just a few millimeters, but the extra could mean too much carryover. The sensor makes that information easy to access. The data can also give indications of what kind of screen media would be most effective on the machine.
Though the sensor is not meant to serve as a screen machine diagnostic tool, the information it provides can point to possible problems with the equipment. One corner of a screen performing differently from the others, for example, may mean further investigation is necessary. The tool allows operators to use the results to determine whether a more technical analysis from an alternative, in-depth system is needed.
The sensor kit arrives in professional casing and includes one sensor, instructions, a USB charging cable and instructions on how to download the Vibration app. The app will be available for iOS and Android phones.
MAJOR dealers will have access to webinars to help them learn to interpret the gathered data.
MAJOR is an innovative global manufacturer of wire screens for the aggregate, mining and recycling industries. Flex-Mat®, the company’s renowned line of distinctive lime-green high vibration screens made with OptimumWire® “The longest-lasting wire” sets the standard in lowering cost of production per ton by dramatically increasing throughput and wear life while eliminating blinding and pegging. MAJOR masters wire quality, screen manufacturing and the screening process, and provides on-site screening performance assessment and training seminars on screen maintenance and screening efficiency to help producers increase their screening performance and profitability. MAJOR is a Haver & Boecker company.