Frequent Conveyor Belt Accidents- Analysis of Conveyor Belt Steel Cord Detection Technology

2025-10-15

Steel-cord conveyor belts, as critical equipment in production lines, are subject to long-term exposure to harsh conditions, high loads, and continuous operation, resulting in a high frequency of damage. If damaged and not promptly replaced, they can easily break, resulting in equipment worth thousands or even millions of dollars being completely destroyed in just minutes. Furthermore, after a belt break, the production line often undergoes lengthy downtime for maintenance and complex recovery procedures, resulting in not only high repair costs but also significant disruption to normal operations and economic profitability, leading to significant direct and indirect losses.

Causes of Many Accidents：

Wire Cord Wear: Long-term operation causes fatigue wear on the wire cord, exposing the wires in severe cases and easily causing belt breakage.

Joint Failure: The non-rigid connection of the wire cord at the vulcanized joint can easily shift when unevenly loaded, leading to tearing.

Foreign Object Scratches: Sharp foreign objects in the material are a major cause of longitudinal tearing in conveyor belts.

Belt Tracking: Severe belt tracking can cause the belt to fold sideways, rubbing against structural components such as roller supports, and ultimately tear.

Material Blockage: Undersized or clogged transfer chutes can cause large pieces of material or impurities to become stuck, resulting in the sudden pressure tearing the conveyor belt.

Part Dropping: When components such as intermediate rollers fall off, the conveyor belt, under heavy load, can be directly pressed against the support frame, where it can be cut and 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.

Therefore, improving conveyor belt reliability, scientifically predicting conveyor belt deterioration trends, and accurately assessing conveyor belt service life are crucial to ensuring the safe and reliable operation of conveyor belt.

Luoyang TST Flaw Detection Technology Co., Ltd. boasts strong R&D capabilities. Its independently developed multimodal AI intelligent safety monitoring platform for conveyor belts uses AI visual image flaw detection and full magnetic detection to perform multiple simultaneous inspections of conveyor belts. This ensures normal production continuity while providing comprehensive and uninterrupted monitoring of the safe service status of the conveyor belt.

This system utilizes advanced predictive analysis technology to scientifically predict potential deterioration in conveyor belt performance, effectively delaying premature equipment failure and delivering the dual benefits of reduced costs and increased profitability for enterprises.

The system accurately captures subtle displacements of conveyor belt cord joints, hidden bulges, foreign object intrusion, signs of deviation, and even complex conditions such as longitudinal tears, transverse belt breaks, minor internal damage to the cord, and surface wear, ensuring every detail is captured.

The system also enables one-touch start and stop monitoring of each conveyor belt during operation, comprehensive fault display, fault reset, damage alarms, and real-time operating status display, enabling unmanned monitoring 24/7.

The image above shows an installation and operation site at a mine. Customers can view wire rope damage records and understand damage trends on the industrial console unit station.

By archiving this data, enterprises can establish a long-term, real-time conveyor belt monitoring mechanism, providing a scientific basis for intelligent mine management.

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