1、Background of Product Development

Steel core conveyor belt is characterized for its advantages such as high tensile strength, strong bearing capacity and stable operation, therefore it is widely used in coal mine, wharf, metallurgy, construction and other industries. However, the joint of the conveyor belt is usually to be twitched, stretched or even broken in the excessive force due to the long-term, high-load operation process of the conveyor belt, or due to the vulcanized joint technology of the belt which is not up to standard in the process of equipment operation; and some unprepared factors in the production process will also eventually result in sudden rupture of the belt, for example, the inner steel core may be corroded due to the erosion of water for the damaged belt skin with the impact of gangue on the belt or the blockage of metals. Especially for the upward belt conveyor with large inclination, long distance and heavy load, once the belt breakage accident occurs, it will destroy the frame of the belt conveyor, damage the equipment and block the transportation roadway, resulting in a long period of shutdown and major economic losses, even casualties, with extremely serious consequences.

Therefore, it is of vital importance to effectively detect the steel core conveyor belt to ensure the safe and reliable operation of the steel core conveyor belt, avoid accidents, prolong service life and save production costs.

2、The Risks of Broken Belt:

(1) it may cause casualties;

(2) it may damage the conveyor belt;

(3) it may damage the conveyor frame;

(4) it may block the conveyor roadway;

(5) it may stop the production;

3、Product Overview

This equipment can effectively detect the condition of steel core conveyor belt in use, prevent the belt from breaking, tearing, and other damages which may affect the normal production to avoid greater safety accidents. The equipment uses X-ray imaging, digital technology, and advanced "fingerprint identification" software technology to process and intelligently identify the generated images, thus it is able to give timely warning.

(1)During the detection, it’s not necessary to stop the conveyor. The internal perspective of the whole conveyor belt will be displayed on the screen like a film, which is clear, intuitive, accurate and reliable.

(2)When there is a problem somewhere in the conveyor belt, such as the corrosion and fracture of the steel core, or even the twitch of the conveyor belt joint, the equipment will give sound and light alarm, and at the same time flash the enlarged picture for the part with problem.

(3) After each detection, the equipment will automatically generate a detection report. The detection report will give a detailed description of all abnormal situations, and will accurately identify the locations of the problem. The lateral error is less than 1 cm, and the longitudinal error is less than 5 cm.

(4)All the images can be saved. Users are able to check images of the current day or the history images, browse the whole conveyor belt carefully to understand the current overall safety situation of the conveyor belt.

(5)The detected image and data can be uploaded to the Internet, which enables you to check the detected images from anywhere as long as the Internet is accessible. The person in charge can know the status of the conveyor belt even at home or on business trips.

4、Benefits for Installation of this Product

(1)It can identify and detect the quality of newly replaced conveyor belts and the vulcanization process of joints;

(2)It can detect and judge the running state of the old conveyor belt intuitively and accurately.

(3)It can avoid the waste caused by blindly replacing or repairing conveyor belts for safety reasons;

(4)It can avoid economic losses such as production reduction or shutdown caused by belt breakage accident.

(5)It can avoid casualties caused by belt breakage accident.

(6)It is possible to arrange reasonably for the maintenance time according to the operation status and production tasks of the conveyor belt, so as to increase the service life of the conveyor belt.

5、Principle of Product Composition

  This product consists of the on-site detection part and the remote-control part with the single mode optical fiber as the connection medium.

The field detection part mainly includes the X-ray generator, X-ray receiver and equipment control host; the remote-control part mainly consists of industrial computer and optical terminal.

6、Physical Structure

7、Product Functions

(1)Remote operation: Equipment operators can operate switching power supply, switching radiation, image acquisition and equipment status monitoring anywhere within 20 km from the installation location of the equipment. All equipment operations and status monitoring can be completed without personnel to the detection site.

(2)Real time display: The running status of the belt will be displayed on the computer screen in real time, allowing users to watch the scene like a film.

(3)Holographic storage: The collected tape data are stored to the hard disk through multi-threading and special disk operation mode, which ensures that the perspective image is not different from the actual tape at processing and replay.

(4)Automatic identification: Without the assistance of personnel, the software automatically identifies the breakage, abnormality and joint twitch of the whole tape, and classifies and lists all kinds of defects for user-oriented maintenance.

(5)Video playback: It is possible to reproduce the whole process of tape operation, and adjust the speed of tape operation, so that users can have a detailed view; by double-clicking at any defect, it is also able to automatically jump to the corresponding defect image location, reducing the user's viewing time.

(6)Defect location: It is possible to locate each defect accurately using the pixel data, and display the location information in the observation window and in the report.

(7)High Magnification: It is possible to observe all kinds of defects, including shredding and rust, by using the principle of magnifying glasses.

(8)Accurate ranging: By simple operation, the distance between any two points in the tape can be measured. The accuracy unit is 1 mm.

(9)Automatic alarm: The alarm limit parameters can be set in the software, which will automatically realize the sound and light alarm when detecting the defects larger than the parameters.

(10)Graphic report: The softer will automatically sort the defect pictures, defect location, defect size and other information identified during the detection process and automatically generate the graphic report simply by a click on the "report" button after the completion of the detection.

(11)Unattended: By operating the "unattended" button in the main interface, the whole detection process can be automatically completed without personnel guarding.

8、Technical Parameter

9、Installation of Products

The following figure shows the product installation diagram.

   (1)The following figure shows the product installation diagram.

(2)Installation in the lower belt position will not affect the normal operation of the belt conveyor.

(3)The product adopts modular design, which can be adapted to the belt conveyor of  any height, width and length.

(4)The product adopts IP57 protection grade, which can be applied to any working conditions and any environment such as the rain, snow, dust and so on.

(5)The weight of the whole machine has been lightened as far as possible so as to enable the installation by 2 persons in 2 hours.

(6)In order to ensure the detection effect and accuracy, it is better to install the equipment in the place where the ground is flat and the tape jitter amplitude is relatively small;  it shall be provide the power supply on the equipment site, with the power supply voltage 90v-265v; the optical fiber shall be installed from the equipment main cabinet and led to the ground monitoring room.

10、Product Maintenance

     This product barely needs maintenance for its metal outer shell, which will ensure no wear and tear for the electronic components inside.

However, it should be pointed out that the product's ray generator has a service life. Ideally, its service life is 25,000 hours. This product can be continuously used for detection, but in order to prolong the service life of the equipment, it is better to carry out regular detection every day or every few days. Because the damage of the belt is a gradual process, the detection frequency will not affect the detection effect, and also can keep the equipment in a good state.

11、Detection Cases