[Belt conveyor intelligent solution] AI conveyor belt longitudinal tear intelligent monitoring system based on laser and visual fusion

In industrial production, belt conveyors are key equipment for continuous material transportation, and their stable operation is directly related to production efficiency and work safety. However, the hidden danger of longitudinal tearing of conveyor belts, once it occurs, will lead to downtime, material waste and even secondary accidents. In response to this common challenge in the industry, East China Machinery launched a conveyor belt longitudinal tear monitoring solution, with laser technology and visual recognition as the core, to achieve intelligent monitoring and abnormal warning of the conveyor belt operation status.

Application scenario: key links, comprehensive monitoring

All-weather monitoring of main transport lanes

For long-distance main conveyor belts, the system scans the full width of the conveyor belt 24 hours a day, especially focusing on vulnerable areas such as joints and vulcanized seams. The laser penetrates the dust to accurately identify cracks to prevent hidden dangers from evolving into large-scale tearing.

Impact damage warning at transfer point

In the transfer process with large material drop, the impact traces of high-speed materials are captured by image, combined with the contour scanning data of linear laser, to establish a two-dimensional deformation model of the belt surface, accurately identify the scratches and structural deformation caused by sharp materials; identify and analyze abnormal deformations that may cause tearing risks, and achieve early warning of tearing risks.

Solving industry pain points: from passive rescue to active defense

Traditional disposal methods VS intelligent solutions

Emergency rescue mode:

(1) Relying on workers' naked eye inspections, a single shift can only cover 30% of the belt area;

(2) The average tear length is 5 meters before it is discovered, and the loss of a single shutdown exceeds 500,000 yuan;

(3) Emergency repairs require the entire line to be shut down for 8-12 hours, affecting the production rhythm of upstream and downstream.

Intelligent defense system:

(1) 7×24 hours real-time monitoring;

(2) Adaptive complex environment: Computer vision and laser compensation algorithms effectively overcome dust and water mist interference;

(3) Intelligent response mechanism: Through visual feature matching and laser contour data fusion, the coordinates of the tear starting point are locked.

Core functions: multi-parameter intelligent monitoring, low-latency abnormal warning

Dual-mode fusion detection

Laser line array scanning + AI visual double verification, cracks are nowhere to hide, and the false alarm rate is reduced by more than 90%.

Intelligent classification of hidden dangers

Based on the deep learning classification model of image features, it automatically outputs three-level warnings of low/medium/high risk and pushes them to the mine safety management system.

Three-dimensional tear positioning

Through the calibration fusion of laser contour scanning data and visual coordinate system, the coordinates of the tear starting point are accurately locked, significantly improving the efficiency of emergency repair.

Technical advantages: Technology empowers precise protection

Laser scanning-precise positioning

(1) Non-contact laser line array scanning, real-time monitoring of the deformation of the entire surface of the conveyor belt;

(2) Breaking through the restrictions of light/dust, responding to tear events with low latency, and gaining golden time for emergency repair.

Visual recognition-AI risk prediction

(1) Equipped with deep learning algorithms, it accurately identifies early tear symptoms such as deep scratches/cracks;

(2) Adaptive to complex working conditions, rapid adaptation to different mining scenarios, and shortening the deployment cycle.

Dual-core collaboration - closed loop of intelligent decision-making

(1) Laser positioning + visual diagnosis data fusion to build a digital twin health file of the conveyor belt;

(2) Dynamically optimize the inspection path, focus on monitoring vulnerable areas such as joints, and improve efficiency.

Future Outlook: Evolution of Intelligent Mine Conveyor Belt Monitoring Technology

In the future, in response to the needs of mine conveyor belt safety monitoring, a multi-parameter fusion monitoring solution is planned to be built. Based on the existing laser and visual technologies, this solution will gradually integrate technical modules such as voiceprint monitoring, infrared thermal imaging and vibration sensors to form a three-dimensional monitoring network of "laser + vision + multi-physical field". The monitoring system will be deeply integrated with the mine industrial Internet to become an intelligent infrastructure supporting the full life cycle management of the conveyor belt, significantly improving the operational reliability of the mine transportation system. Provide intelligent state perception and decision support for mine safety production.