Steel cord conveyor belts, as key equipment in production lines, operate under harsh conditions, high loads, and continuous operation for extended periods, resulting in a high frequency of damage. Failure to replace damaged belts promptly can easily lead to belt breakage. Furthermore, after the belt breakage, the production line often requires lengthy shutdowns for repairs and complex recovery processes, incurring high maintenance costs and severely impacting the company's normal operations and economic benefits.
**Steel Company Conveyor Belt Breakage Accident:**
A steel company in Henan Province experienced a conveyor belt misalignment and tearing accident caused by a slippage at the joint. This accident not only severely damaged the equipment but also caused the entire production line to shut down for several days, resulting in substantial losses.
**Mining Company Conveyor Belt Accident:**
A mining company in Shanxi Province experienced a conveyor belt tearing accident due to the breakage of the internal steel cable. This caused a 26-hour production interruption and significant economic losses.
Causes of Numerous Accidents:
**Wire Rope Core Wear:** Long-term operation leads to fatigue wear of the wire rope core, which can severely expose the wires and cause belt breakage.
**Joint Failure:** The wire rope at the vulcanized joint is not a rigid connection, making it prone to displacement and tearing under uneven stress.
**Foreign Object Scratches:** Sharp foreign objects in the material are a major cause of longitudinal tearing of the conveyor belt.
**Belt Misalignment:** Severe misalignment can cause the belt to fold on its side and rub against structural components such as idler rollers, eventually leading to tearing.
**Material Blockage:** Insufficiently designed or blocked transfer chutes can cause large pieces of material or impurities to become stuck, and the instantaneous pressure can tear the conveyor belt.
**Component Falling Off:** When components such as intermediate idlers fall off, the conveyor belt, under heavy load, will directly press against the support and be torn by its edges.
**Auxiliary Equipment Failure:** Improper installation or loosening of accessories such as vibrator liners and crusher hammers can also cause internal impact and scratches on the belt.
In the wave of rapid technological development, Luoyang TST Flaw Detection Technology Co., Ltd., with its strong R&D capabilities, continuously leads the industry's progress through continuous innovation.
We have independently developed a multi-modal fusion AI intelligent safety monitoring system for conveyor belts. This system utilizes AI visual image flaw detection combined with full magnetic detection to perform dual synchronous inspection of conveyor belts, building an impenetrable defense for safe production in various enterprises and helping them operate efficiently and safely.
This system can perform comprehensive and uninterrupted safety monitoring of various types of damage to conveyor belts, such as steel cord joint displacement, belt breakage, and steel cord damage, while normal production is underway.
It also employs advanced predictive analysis technology to scientifically predict potential deterioration trends in conveyor belt performance, effectively delaying premature equipment failure and bringing the dual benefits of cost reduction and increased efficiency to enterprises.
This system can accurately capture minute displacements, hidden bulges, foreign object intrusion, and signs of misalignment in conveyor belt steel cord joints, as well as complex conditions such as longitudinal tears, transverse belt breaks, minor internal damage to the steel cord, and surface wear, ensuring that every detail is under control.
The system also enables full magnetic non-destructive testing and AI visual recognition of damage and location for each conveyor belt during operation. It features one-click start/stop detection, comprehensive fault display, fault reset, damage alarm, and real-time operating status display, achieving 24/7 unattended monitoring.
The image above shows the installation and operation site at a mine. The customer can view the damage records of the wire ropes and understand the damage trends at the industrial control console unit.
By archiving data, the system helps enterprises establish a long-term real-time conveyor belt monitoring mechanism, providing a scientific basis for intelligent management of smart mines.
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