ONE BRAND
Poing near Munich, March 24th, 2025 – REMA TIP TOP presents MCube BRD2, the latest generation of Belt Rip Detection (BRD). The innovative sensor technology significantly improves the precise real-time analysis of steel cord conveyor belts and supports predictive maintenance. Belt rips are detected quickly and reliably. An automatic halt prevents significant damage and reduces repair costs and expensive production downtime to a minimum - a real added value for plant operators in the mining and heavy industries. MCube BRD2 is part of the comprehensive REMA Engineered Technologies portfolio that REMA TIP TOP provides to optimize the maintenance of conveyor belts.
"Conveyor belts are the backbone of efficient material flow systems in heavy industry. With the enhanced MCube BRD2, we are setting new standards in the efficiency and availability of conveyor systems," says Daniel Kasperek, Head of REMA Engineered Technologies at REMA TIP TOP. "Thanks to the optimized integration with our proven MCube sensor loops, the length of a possible belt break is limited to the distance between two sensor loops".
MCube BRD2 features inductive MCube sensor loops integrated into the conveyor belt, available for belt widths from 650 to 3,200 mm (36 to 96 inches). They consist of 2.5 mm thick endless wires with two or three loops and RFID tags for contactless identification. An optimum loop spacing of the recommended 50 m ensures fast rip detection and minimizes the risk of serious longitudinal cracks. The new version is specially adapted to detect the REMA TIP TOP sensor loops integrated in the conveyor belts, but remains versatile and is also compatible with other common sensor loops. The cross-belt system monitoring can be integrated during production or retrofitted. Depending on the installation, the system is mounted above or below the carcass.
An initial scan creates a digital twin of the conveyor belt that is continuously compared to real-time data. Critical signal levels can be individually defined for early response to signs of wear. The system continuously provides data on the position and status of the sensor loops, as well as the last ten status changes of each loop in real time. The data can be displayed on the local controller screen or read out remotely. This provides the operator with early warning of impending wear-related failures, allowing proactive action to be taken.
The improved belt rip detection with MCube BRD2 is the result of a close cooperation between REMA TIP TOP AG and Becker Mining Systems. Becker Mining Systems' systems have proven themselves in more than 250 installations worldwide, covering hundreds of kilometers. The stainless steel housing of the MCube BRD2 system is resistant to dust, water and corrosion (IP65), making it ideal for use in mining and heavy industry. With an operating range of 0°C to +50°C in the standard version, as well as special versions for firedamp and very harsh environments (-43°C to +50°C), the system remains reliable even under the most difficult conditions.
MCube Portfolio: The Modular Conveyor Diagnostics System
MCube BRD2 is part of the comprehensive REMA Engineered Technologies portfolio, providing REMA TIP TOP with the ability to continuously optimize the maintenance of conveyor belts. The combination of high quality technology, sustainable system integration and strong service makes MCube the preferred choice for conveyor system operators worldwide. In addition to belt rip detection, the portfolio includes:
- MCube BTM – Belt Thickness MeasurementNon-contact wear measurement of the carrying side of the belt in just one revolution - ideal for strategic maintenance.
- MCube SCS – Steel Cord ScannerReal-time structural analysis of belt splice and steel cord carcass for defective, corroded or broken cables during operation.
- MCube X-RayHigh-resolution X-ray inspection for precise detection of defects and anomalies in materials and products in industrial conveyor systems.
With MCube BRD2, REMA TIP TOP sets new standards in conveyor belt diagnostics and offers an intelligent, integrated solution for maximum operational reliability and efficiency. This enables REMA TIP TOP to provide customers with comprehensive support from conveyor belt to service - all from a single source.
