Ribbon Tear Localization AI Inspection System

1. Industry status quo

Belt conveyor system: The Core challenge to Ensure the safety of continuous material transportation and the solution to intelligent early warning​

As a key hub for modern industrial material transportation, belt conveyors, with their efficient and continuous conveying capacity, have become indispensable infrastructure in core industrial fields such as ports, mines, steel and metallurgy, chemical raw materials, energy and power, building materials and cement, and have a decisive impact on maintaining the safe and stable operation of production processes.

2. Industry pain points:

​Industry pain point: Frequent risks of conveyor belt damage and tearing

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In harsh industrial environments, belt conveyor systems are subject to high-intensity operating pressure all year round, and the potential failure risks they face cannot be ignored:

• ​Continuous high-load operationLong-term and uninterrupted heavy-load transportation is highly likely to accelerate the fatigue aging of conveyor belts and key components.
• ​Abnormal material impactAbnormal characteristics of the conveyed materials (such as sharp edges and corners, oversized dimensions) or the impact of external foreign objects (such as accidentally falling metal parts, ores) pose a risk of instantaneous damage.
• ​Structural risks:Problems of the equipment itself, such as idler roller failure, roller centering offset, improper installation or commissioning of the material guide chute or cleaner, continuously act on the weak areas of the conveyor belt.

​Severe consequences: Accumulation of hidden damage and sudden failure​

The combined effect of the above factors can easily cause local scratches on the surface of the conveyor belt and damage to the structural layer. What is particularly serious is that these damage points may develop into imperceptible ones in subsequent operationsHidden longitudinal tear expansion source. Once the tear occurs suddenly and spreads:

• ​Cause significant direct asset losses:The risk of the entire conveyor belt being scrapped has significantly increased.
• ​Cause unplanned downtime:The emergency repair process was complex and time-consuming, forcing the production line to be disrupted and resulting in huge capacity losses.
• ​High restoration cost:Even if partial tearing is ready for repair, the required professional repair techniques, downtime and labor input costs far exceed those of conventional maintenance.

3. Solutions

​Breakthrough direction: Intelligent state perception and tearing warning​

The traditional manual inspection or post-event remediation mechanisms have been difficult to meet the requirements of modern industry for continuous production and asset security. Therefore,How can advanced sensing technology, data-driven analysis and intelligent algorithms be used to achieve early, accurate and reliable warnings of potential tearing risks of conveyor beltsIt has become a high ground of safety technology that the entire industry urgently needs to overcome and is also a core link in building an intrinsically safe production system.

WT-BTLS-AI Intelligent Positioning and Detection System for Belt TearingIt is an intelligent system based on AI and stereo vision, aiming to detect and locate abnormal tearing problems of coal belt conveyors in real time. It captures and analyzes the status of the high-speed running belt in real time through a dedicated intelligent camera deployed under the belt, effectively identifying serious defects such as transverse cracks, vertical cracks, longitudinal tear seams and tear overlaps. Once a risk is detected, the system can promptly trigger the automatic control mechanism of the belt conveyor. The accompanying B/S architecture data platform provides users with visual support, including real-time detection images, result analysis, transportation safety monitoring and equipment control interfaces. Its application has significantly enhanced the immediate response capability and intelligent management efficiency of belt tear detection in the mining industry.

4. Core Functions

1. AI Visual recognitionIntegrating industrial cameras with deep learning algorithms, it actively detects and intelligently identifies belt tear marks (transverse/longitudinal cracks, openings, overlaps, etc.).
2. ​Precise damage locationMonitor the belt operation status in real time, accurately calculate and report the specific location where the tear occurs.
3. ​Intelligent linkage responseImmediately trigger the sound and light alarm when an abnormality is detected, and communicate and link with the PLC/ control system to achieve immediate automatic shutdown protection in case of damage.
4. ​Self-cleaning of vision:Integrated with an automatic dust-cleaning mechanism, it effectively removes dust and debris from the lens, ensuring a continuous clear monitoring field of view and adapting to harsh working conditions.
5. ​Remote monitoring and controlProvide standard communication interfaces (such as OPC UA, Modbus TCP), seamlessly integrate with the centralized management platform, and support real-time monitoring and centralized management on both PC and mobile terminals.
6. ​Convenient non-contact installationThe detection unit is deployed beneath the belt, featuring non-contact measurement. It is easy and quick to install without the need for a complex calibration process.
7. ​Modular scalabilityIt adopts a modular architecture design, flexibly combines hardware to expand the monitoring range, and is compatible with direct control instructions from mainstream PLCS/frequency converters.
8. ​Data visualization PlatformThe Web-based B/S platform provides real-time visualization of detection status, structured data storage and historical record playback analysis functions.

5. Technical Principles

An integrated monitoring system based on AI and stereo visionAnalyze the images through real-time algorithms to accurately determine the state of the target area. ​The high efficiency, accuracy, high speed and strong environmental adaptability of stereo vision technologyPerfect matchOnline, non-contact automated inspection and quality control required by the production lineRequirements.

In high-speed coal transportation, etcDynamic sceneBelow, its image capture is completed instantaneously. ​Specialized active stereo vision sensor(Global exposure/high speed/high definition/high dynamic range) coordinationTerminal intelligent designSupport the high-speed coal processingMillimeter-level accuracy, 25 frames per secondReal-time online monitoring.

The highlight of the on-site application lies inOutstanding environmental compatibilityandNon-contact measurement characteristic(No calibration required, no on-site modification needed), the project implementation is prompt and maintenance is simple. This characteristic establishes its positionThe preferred solution status in the safety monitoring application of belt conveyors​。

6. Technical parameters

7. Application scenarios

​WT-BTLS-AI Tearing AI Location Detection SystemSupportInstall and use immediatelyApplicable toSteel, coal mines, ports, power plants, chemical plants, cement plantsAnd many other industries. In the systemVisual inspection belt detectorforContactless installation​，​Convenient to implement​。

Flexible installation location: According to the actual situation of the belt conveyor site, it can be installed inAbove or below the beltAppropriate place. ​Micro and special technologyProvide professional engineering support to assist youDetermine the optimal solution. Welcome to consult our technical engineers at any time.