Bekaert

About Bekaert

As a global leader in material science and steel wire transformation, Bekaert’s expertise extends beyond just steel. They develop innovative solutions across diverse markets, ranging from new mobility to low-carbon construction and green energy. Bridon-Bekaert Ropes Group, one of Bekaert’s divisions, offers both steel wire and synthetic rope solutions. One of their key offerings is Ropes360: a service that provides comprehensive support in all aspects of rope management.

With Ropes360, Bekaert goes beyond producing and selling ropes: they offer a full range of services, including inspection, maintenance, and replacement. As a single point of contact for all rope-related needs, Ropes360 is structured into four phases: pre-use, installation, lifetime optimization, and retirement.

Streamlining lifetime optimization

Bekaert wanted a device that plays an essential role in the third phase, where the goal is to boost the operational lifespan of ropes. They needed a mobile visual inspection tool specifically designed for ropes with diameters ranging from 55 to 110 mm. Existing mobile inspection technologies, known as Magnetic Rope Testing (MRT) devices, use magnets to detect internal anomalies.

While these MRTs are the industry standard in rope testing, they have limitations. They can only detect anomalies in the magnetic field. This makes MRTs unsuitable for synthetic ropes and unable to measure geometrical rope parameters like diameter, ovality, waviness and overall surface condition.

Additionally, MRTs are not efficient: they always require an additional visual inspection by an experienced technician. While the MRT finds and identifies the malfunction, an operator has to track it down and take images - making the process needlessly complicated and time-consuming.

Bekaert wants to streamline this process by developing a visual inspection device that operates in tandem with an MRT. This innovation should detect anomalies and capture images simultaneously, providing an efficient visual inspection of the rope.

Reimagining existing prototypes

Bekaert leveraged their previous acquisition of VisionTek S.R.L, an Italian firm specializing in rope inspection for ropeways, and built on existing technology. While the prototype was functional, it wasn't fit for mass production or heavy duty industrial applications.

The design was very complex, with numerous protruding parts and significant tolerance issues. Production was expensive and time-consuming, making it challenging to produce at a reproducible quality and hindering its potential for broader market adoption.

Leveraging external expertise

After exploring the market thoroughly, Bekaert asked Comate to assist in developing their new design. As a full-service engineering company, Comate was able to complement Bekaert’s in-house expertise.

With our diverse range of talent, we can tailor our team to meet any project’s needs. Our internal certification experts also proved to be major assets: they ensured all standards were addressed from the start and closely monitored throughout the implementation.

Collaborating on innovation

Mechanics were our initial focus: the device needed to be lighter, sturdier and more efficient. Our first step was to gather all existing knowledge and explore various iterations for the essential components. In a following step, we integrated these components into concept architectures.

Balancing the device’s robustness and usability was a challenge. It had to withstand tough conditions in mining and oil & gas environments, often in extreme temperatures. In marine settings, it had to run unattended for weeks on heavy ropes supporting up to 600 kg. But it also had to be light and manageable enough for manual placement on high ropes, like those in ski elevators.

Another difficulty was getting accurate measurements. With ropes being greased and dusty, or having loose wires passing through the device, it was crucial that it was kept clean. Precision parts like cameras and lenses needed protection, but also needed to be cleanable with solvents.

While we detailed the new device, Bekaert tested their prototypes even further – brainstorming and gaining insights every day. As we were going through a learning process simultaneously, there were shifts in requirements – sometimes requiring us to go back to the drawing table. But this iterative approach is common in our industry - and we are prepared for it. Comate's flexibility enabled a close collaboration, ensuring that we created the best possible product together.

Enhancing rope inspection

We engineered a vision system designed to mount over a rope, allowing it to pass through. The key component, a C-frame, was streamlined from the previous prototype's complex design. By reducing the number of fits, we improved accuracy. We also machined or turned all tolerance-sensitive parts and made shields out of sheet metal. We minimized the device’s weight - all while making sure it met the safety requirements to operate in demanding environments.

The C-frame housed four high-quality cameras, while the internal measuring chamber was specially treated to minimize reflections. As the rope passes through, the cameras capture direct images of the rope – enabling precise quality control without requiring a human operator.

In terms of design, we ensured that the exterior reflected the interior’s technical sophistication. It ensures robustness and reliability, even in the toughest conditions. To guarantee ease of use, we made touchpoints accessible for use with protective gloves. To ensure efficiency and safety during operation, we clearly labeled all critical parts.

To tie it all together, we integrated Bekaert’s brand guidelines and signature colors. This way, the device not only meets high performance standards but it also visually aligns with Bekaert's trusted and recognizable identity.

A partnership for improved performance

Through close collaboration, we crafted a device that is modular, sturdy, and scalable for production. In the final product, we fused Bekaert’s extensive experience with Comate’s innovative mechanical and electronic design. This new innovation promises to optimize not only the lifetime of ropes - but also the management of it.

At this time, we’ve developed a mid-range device tailored for ropes between 55 and 110 mm in diameter. Future plans include versions catering to smaller and larger cable diameters, up to 200 mm. All devices are undergoing rigorous testing in Bekaert’s test centers – with the field tests coming closer every day.