Components · Rip Prevent+ · Zone 05
On a high-value belt, an undetected longitudinal rip can become a six-figure replacement event before anyone reacts. Rip Prevent+ watches the whole belt using AI and the conveyor's own operating data — no sensors in the belt — to flag a rip condition before it propagates.
01 / Engineering logic
AI on the conveyor's own data — not sensors in the belt.
Developed with SHG, a German conveyor-monitoring specialist, Rip Prevent+ builds a data-driven model of your conveyor and uses AI to spot the anomalies that precede a rip — then signals the PLC in real time.
02 / Rip Prevent+ architecture
The architecture, up close.
Rip Prevent+ is a single, sealed unit that taps the conveyor's electrical and operating signals, runs the AI model on-board, and drives the PLC through configurable relays — monitored over a secure web interface.
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Key inputs
Electrical power, mass flow, conveyor speed, idler dimensions and belt dimensions, taken via current transformers, not belt sensors.
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On-board AI model
A data-driven calculation model of the conveyor runs anomaly detection continuously, 50 times per second.
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Web-based monitoring
Secure, multi-user access over Ethernet (TCP/IP), with an intuitive dashboard: rip-risk indicator, up/downtime, anomaly and rip signals, event list and utilisation rate.
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PLC relay logic
Three configurable relay outputs map to events: rip event → relay 3; anomaly detection, drive failure and overload → relay 2; maintenance recommendation and condition monitoring → relay 1.
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Response
Configured during commissioning: alarm the control room, trigger an automated belt stop, or both, agreed with site engineering.
Architecture · up close
03 / The range
The Rip Prevent+ system.
From the brochure. Engineering confirms configuration against your conveyor.
Technical specifications
Rip Prevent+ System
- Belt width: 600–6000 mm.
- Belt speed: up to 12 m/s.
- Belt types: EP, ST and special belts.
- Temperature range: −20 °C to 55 °C.
- Humidity: 20–90% RH, non-condensing.
- System outputs: 3× open relays (max 250 V, 6 A); 1× Ethernet TCP/IP; 1× analog output 0–10 V (max 28 mA).
- Input power: 88–264 VAC / 125–270 VDC.
- IP class: IP67 (IP69K on request).
- Conformity: CE, UL, RoHS (ATEX on request).
- Dimensions: 300 × 330 × 120 mm.
Add-ons
Drive Monitoring
Early motor-failure detection from high-resolution electrical parameters, including unusual heat development.
Massflow Calculation
Mass flow from averaged bulk density, for load management and overload detection.
Condition Monitoring
Stores up to 5 years of high-resolution data for AI plant-condition assessment and early wear detection.
Energy Efficiency Improvement
Targets optimal power per tonne conveyed to cut energy demand and CO₂, with component analysis and ROI.
Maintenance Support
Component-level analysis against a database and site parameters, for planned maintenance.
Electrical Network Analysis
Identifies and corrects electrical-network quality issues in near real-time to reduce component wear.
Add-ons are free, continuously developed modules that integrate with the system.
Rip Prevent+ is matched to the belt — start with a suitability assessment.
No protection system eliminates the possibility of belt damage; suitability and detection limits are assessed per belt. Send your belt and conveyor details and we'll confirm fit.