Conveyor Belt Edge Defect Detection Using Non-Contact Sensors
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Solution Overview
Problem
Existing devices are unable to accurately measure defects and determine the location of such defects in the edge areas of conveyor belts due to instability caused by vibrations and lateral movements, which can lead to rapid damage escalation and significant production losses.
Innovation Solution
A device with non-contact measuring strips equipped with distance sensors and magnetometer sensors, arranged in a differential system, to measure and analyze the geometry of belt edge areas, ensuring accuracy despite transverse, vertical, and longitudinal vibrations, and harsh operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If contact-based measuring rollers are used to measure belt thickness, then measurement can be performed during operation, but the measuring system is affected by belt vibrations and lateral movements reducing measurement precision
Solution Approach 1:
The patent replaces mechanical contact-based measuring rollers with non-contact optical distance sensors (laser or ultrasonic). This substitution eliminates mechanical contact between the measuring system and the conveyor belt, thereby removing the source of measurement errors caused by vibrations and lateral movements. The optical sensors can accurately measure belt thickness and detect edge defects without physical contact, maintaining measurement precision while enabling continuous monitoring during operation.
2Measurement precision
If non-contact distance sensors are used, then measurement precision is improved, but the system cannot accurately determine defect location due to belt transverse displacement
Solution Approach 1:
The patent divides the measurement system into multiple segments: distance sensors for thickness measurement, separate sensors for detecting the position of belt edges relative to the roller axis, and encoders for tracking belt movement. By segmenting the measurement functions and combining the data from multiple sensors, the system can accurately determine both the presence and location of defects even when the belt undergoes transverse displacement.
Solution Approach 2:
The system continuously monitors the position of the belt edges and the location of measured defects, providing feedback to the control unit. This feedback mechanism allows the system to compensate for belt transverse displacement by adjusting the reference frame for defect location reporting, ensuring accurate spatial information is maintained despite belt movement during operation.
3Reliability
If the measuring system is fixed relative to the belt, then measurement consistency is improved, but the system becomes complex and difficult to install
Solution Approach 1:
The patent employs sensors that automatically adapt to the belt's position and movement characteristics during operation. The system self-calibrates by continuously monitoring belt edge positions and adjusting measurement references accordingly, eliminating the need for complex mechanical fixing systems or manual alignment procedures. This self-service approach maintains measurement consistency while significantly reducing system complexity and installation difficulty.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid identification and precise location of worn areas in conveyor belt edges, allowing timely repairs and preventing extensive damage, thus enhancing operational safety and reducing production losses.
Implementation Method 1
distance sensors (8), the signals from which are differentially connected to the analyzer (5)
Implementation Method 2
at least one bar-observer (10) equipped with a magnetometer sensor (17) or several magnetometer sensors (17)
Data Source
Figure 1~2a
AI summary
A device for measuring defects in edge areas of a conveyor belt (1), especially defects of a rubber carcass of said belt edges of conveyor belts equipped with steel cords (11) forming steel core of the belt, according to the invention is distinguished in that it contains a support structure (4) located on both lateral sides of the conveyor belt (1), on which distance sensors (8) are arranged perpendicular to a direction of movement of the conveyor belt (1), in a lower run of a conveyor for producing signals which are continuously transmitted to connected by signal transmission connection electronic analyzer (5) and recorded. Wherein on each of two brackets of the support structure (4) is mounted measuring strip (3) with attached to each of these measuring strips, opposite to each other, distance sensors (8), differentially connected to the analyzer (5) allowing measurement of the width h1 of the conveyor belt (1) and wherein each of the measuring strips (3) contains at least 3 distance sensors (8) which are paired with each other respectively on both sides of the conveyor belt. In addition, barsobservers (10), in the form of magnetometer strips (10) equipped with at least one magnetometer sensor (17) or more, are mounted on each support structure (4) bracket. A further aspect of the invention proposes a method for measuring defects in edge areas of a conveyor belt (1), particularly defects of a rubber matrix of the belt edges of a conveyor belts equipped with steel cords (11) forming a steel core of the belt, by detecting and determining the location of occurring defect (2) in the edges of the conveyor belt (1) using a device for measuring defects in the edge areas of the conveyor belt (1).