Heavy Duty Monitoring Equipment
for the Bulk Handling and Processing Industries

Founded in 1983, Rotech Systems manufactures and supplies high-quality, reliable equipment worldwide. Their products monitor and measure the speed, position, and direction of rotating shafts.

Rotech Systems is the world’s leading manufacturer of high-quality monitoring solutions. They have an unparalleled reputation for reliability, durability, and quality.

Their products feature tough, strong, heavy-duty construction. They are designed to operate maintenance-free for years, even in harsh industrial environments like quarries and mines. Installation is simple and quick.

Main applications are in the bulk handling and processing industries. Protecting conveyors, elevators, screws, crushers, mixers, etc. anywhere were slowing down or stoppage will cause product spillage, blockage, etc. and incur downtime, lost production, cleaning up, spoilt product, etc.

Equipment can give visual and/or audible alarms plus shutdown items of plant for a speed reduction of only 5% (adjustable 5% to 90%)
Protects against conveyor belt slip, v belt slip, chain breakage, mechanical failure, stoppage, blocking, jamming, etc.

Industries using “Rotech”: Food, Textiles, Glass, Grain, Power generators, Fertiliser, Sand, Gravel, Roadstone, Coal, steel, Ore.

Introduction

Rotech Motion Sensors/Encoders have applications in systems that transport or process materials using conveyors, elevators, screws, crushers, mixers, and similar equipment.

Food, Grain, Pharmaceuticals, Chemicals, Sand, Stone, Cement, Ore, Coal, Ash, in Factories, Quarries, Mines, Power Utilities, and Dock Installations are all excellent examples.

A single conveyor may run without problems for long periods, but not forever. Eventually, it starts to slip or slow down. If no one takes quick action to switch off the conveyor, crusher, or feeding plant, a major spillage can result.

In a large plant with many conveyors and drives, each additional drive element increases the potential for problems.

The costs of clearing up a spillage are not simply the costs of a man with a shovel, this is the tip of the iceberg, they can include:

• Damaged belts (Conveyor & Drive, “V”, Flat, Etc.)
• Damaged Plant & Machinery.
• Mechanical Diggers, Front Loaders, Etc. to clear up Grain, Sand, Stone, Ore, Coal, Etc
• Contamination to Food, Pharmaceutical, Chemical, products, resulting in rejection and waste
• Although these costs may seem considerable, they often pale in comparison to the real cost.
• The REAL COST is the loss in Production, Throughput and Revenue whilst cleaning up
• When a plant stops producing, losses can reach hundreds or even thousands of pounds per hour. Rotech Motion Sensors/Encoders offer simple, low-cost, and highly reliable protection against these problems.

General Description

The Rotech range of monitoring equipment includes motion sensors/encoders, vibration sensors, and associated speed relays.

The Heavy Duty Sensors are installed on the end of the shaft or on the belt being monitored. They send an electrical signal proportional to the speed of the shaft/belt to a suitable control unit.

The control unit can be a “Rotech” Speed Relay, a Programmable Controller, a Computer, Data Logger device or other proprietary control equipment.

The alarm level of the control unit is set to just below the normal running speed of the shaft.

In the event of the shaft/belt slowing below the set level, the control unit operates and can be connected to give an alarm to the operator and/or shutdown preceding items of plant.

Advantages of “Rotech”

“Rotech” heavy duty motion sensors and encoders combine many unique design features to give
the customer:-

• Simple installation
• High performance
• High reliability
• Price benefits

Installation

For shaft encoders one hole is drilled and tapped into the end of the shaft to be monitored, gives simple, uncomplicated, fast installation.

One type of unit covers all types of drives, conveyors, elevators, crushers, etc. allowing standardisation of designs, installation and spares.

There are no target discs to design, manufacture and install.
No sensor brackets to design, manufacture and install.
Without guards to design, manufacture and install.
No on – plant adjustment or setting up required.

The shaft carries the “Rotech” unit and moves with it; shaft end float, belt adjustment, and other factors do not affect it.
If you cannot access the end of the shaft, you can use our wheel encoders directly on the belt.

Bolt a piece of unistrut to two uprights across the return belt, then bolt the wheel encoder to the centre of the unistrut using the integral bracket. This bracket lets the wheel encoder hang down onto the return belt and move freely with it.

Again one type of unit covers all types of drives, conveyors, elevators, crushers, etc. allowing standardisation of designs, installation and spares.

Performance

“Rotech” Motion Sensors/Encoders are digital pulse generators guaranteed accurate to within 0.5%, they cannot drift and require no checks or periodic calibration.

With pulse output rates from 1 Pulse per Rev to 1000 Pulses per Rev, drive speeds from 5000 RPM down to 0.03 RPM (2 Revs/Hour) can be accurately and reliability measured and monitored.

Reliability

“Rotech” units are designed to operate and survive in even the toughest industrial environments, they have been particularly developed for the Quarrying and Mining industries, however their compact size makes them just as suitable for light industries such as :-

Food Production, Animal Feeds, Farming, Pharmaceutical, Baggage Handling, Escalators & Moving Walkways, etc.
Heavy Duty castings, Heavy Duty sealed bearings and robust fully encapsulated industrialised electronics form the tough strong core of these units.

Extensive use is made of modern engineering adhesives and sealants to double up on the traditional precision assembly methods and ensure even greater reliability.

‘O’ ring seals on end covers, grease chambers, spring loaded shaft seals and liquid tight flexible conduit and glands complete these units to give outstanding levels of protection and ensure the highest levels of reliability and operational life.

Price

Installed price is competitive or possibly lower than alternative methods, ultimate in operational life and reliability is an added bonus.