A New Level
The Leveltec team are focused and determined, working within their purpose-built manufacturing facility to deliver high quality engineering solutions that exceed expectations every time. It is said that everything old is new again and that is certainly the case when it comes to the new application of tried and tested tilt switches.
The Last Line of Defence
Tilt switches have been in existence for many years and it is little wonder they are still in operation right across the mining sector. Their simple design makes them intrinsically robust, reliable and economical – ideal for protecting the transfer of bulk solids from pit to port as well as protecting critical infrastructure. Even in applications that utilise radar and other complex methods to monitor the flow of ore, coal or other minerals, the rock solid tilt switch still plays an important role as the last line of defence in the case of a chute blockage or conveyor system failure.
Leveltec has been designing and manufacturing tilt switches in Australia since the 1980s but in 2013 the company expanded to become a service agent, offering customised solutions for bulk handling control across the mining, steel and food industries. They have grown from initially providing switches and hardware to building and implementing systems to monitor the flow of bulk solids, gather data through mainly wireless networks and provide failsafe shutdowns in emergency situations.
Tilt Switches
Occam’s Razor states that ‘the simplest solution is almost always the best solution.’ This is certainly the case with tilt switches, which come in a couple of variations according to their intended use. Mercury tilt switches are a fast acting and reliable passive device that operates on a simple mechanical principle. They require no electronics for control and do not hold a charge. Leveltec’s tilt switches can also operate on ultra-low and low voltage, up to 250V AC. This makes them suitable for use in potentially explosive or hazardous environments when they are used in an intrinsically safe circuit. No additional controller is required to operate these switches, which makes them significantly more cost effective than others in the market.
The very nature of this design makes the switch robust and reliable. They are used at every transfer point in the movement of solids – literally from the bottom of the pit, through crushers, conveyors, bins, trains and ultimately a ship loader if that is the final point of contact. If a chute becomes blocked or there is a failure in a conveyor and material starts to build up, it will trigger the tilt switch and activate a high-level alarm. This can either initiate action by a supervisor or be integrated into a system that shuts down that part of the line.
In high wind or high vibration applications, a snap tilt switch can be used. These are internally dampened to reduce the likelihood of false tripping. Leveltec’s unique design incorporates a strong, smooth body to resist the buildup of materials and resist wear. The switch can also be housed in a wear resistant body for use with high abrasion or highly corrosive materials. In this case, the client need only replace the housing as part of their regular wear maintenance practice, as the switch itself remains undamaged. This reduces both cost and unscheduled downtime.
Electro-Mechanical Integration
There is a good reason why these switches have been in continuous use for over 30 years. They are robust, reliable and economical but can also be integrated into the very latest IoT and Industry 4.0 systems – adding a mechanical fail-safe to the world of complex electronics.
It is the growth in this area that has fuelled Leveltec’s evolution into a total solution provider and direct supplier to every multi-national mining company in Australia. They have put boots on the ground at each site and tailored a turnkey solution to meet the particular needs of each client. In many cases this required designing bespoke switches and sensors to increase sensitivity and reliability while reducing ongoing costs.
The increased demand for their services in these critical areas led Leveltec to partner with world leading companies in Germany and the UK to compliment their own range of Australian manufactured components. They have hand picked specific products to create synergies in their solutions – making them adaptable to almost any industry. Their origins in coal have now expanded to include copper, lithium, zinc, steel and aluminium manufacturing, transportation, shipping ports and even the food industry.
Holistic Approach
Leveltec are fiercely proud of their Australian manufacturing history and this is evident in their 10-year anniversary celebration in 2024. They have plans to increase the level of their local manufacturing by 30% in the next year, which will also create jobs at their Gloucester base in regional NSW.
The quality and scope of their products goes hand-in-hand with the vast experience of their technical team and the level of service they offer every client – their value triangle.
This three-pronged approach has allowed them to group specific products and systems together to provide a simplified and efficient process to new customers and resolve industry challenges along the way. This includes site visits to witness the operation firsthand, before putting pen to paper on a proposed solution.
An holistic approach such as this has created enormous value for clients over the past 10 years. The implementation of relatively low-cost wireless networks allows data to be collected on a constant basis, which reveals trends and allows detailed analysis of a variety of assets. By adopting rotational strategies for parts and sharing those strategies across a group of sites across Australia, it is possible for each member of the group to benefit from a standardised approach to maintaining their fleets of equipment.
Leveltec carried out such an undertaking for one client in the dragline space and virtually eliminated unscheduled downtime for that operation. This improved level of data collection and analysis was implemented over three years and helped the client move from a simple preventative maintenance structure to a comprehensive predictive maintenance strategy.
This provided commonality among the sites within the group with regards to spares and a single point of contact for direct support at any time. Such a unified approach continues to deliver faster turnaround for scheduled maintenance and almost zero unplanned downtime. The cost savings from this programme have been significant, particularly with machines that cost hundreds of thousands of dollars an hour when they are offline.
Because Leveltec are within close proximity to their customers (a new branch will soon be opened in WA), they also offer a back-to-base service to increase the life of assets in the field, again coupled with a structured rotational service programme.
Future Facing
Leveltec are excited about their future in Australia and the areas of growth that will enable them to offer even greater levels of service to new and existing customers. They have created a collective of world-class products and moulded them into well-constructed turnkey solutions for their clients around the country and now overseas.
They specialise in bulk material handling, operator interfaces and control equipment, power distribution and switchgear, renewables (solar switches and solar combiners), cable handling, cable chain and protection systems, automation, electronics and wireless monitoring. These are areas they understand implicitly and under each banner they have compiled class-leading products, personalised service and a strong knowledge base to deliver the level of outcomes expected by modern industry.
After 10 years, Leveltec have integrated proven technology with well-constructed systems to deliver a new level of service and efficiency for their clients. Watch this space.
Source:
Leveltec
02 6558 9264
