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Inspection Robotic UGV Platform and the Procedure for an Acoustic Signal-Based Fault Detection in Belt Conveyor Idler

Author

Listed:
  • Hamid Shiri

    (Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology, 50-370 Wrocław, Poland)

  • Jacek Wodecki

    (Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology, 50-370 Wrocław, Poland)

  • Bartłomiej Ziętek

    (Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology, 50-370 Wrocław, Poland)

  • Radosław Zimroz

    (Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology, 50-370 Wrocław, Poland)

Abstract

Belt conveyors are commonly used for the transportation of bulk materials. The most characteristic design feature is the fact that thousands of idlers are supporting the moving belt. One of the critical elements of the idler is the rolling element bearing, which requires monitoring and diagnostics to prevent potential failure. Due to the number of idlers to be monitored, the size of the conveyor, and the risk of accident when dealing with rotating elements and moving belts, monitoring of all idlers (i.e., using vibration sensors) is impractical regarding scale and connectivity. Hence, an inspection robot is proposed to capture acoustic signals instead of vibrations commonly used in condition monitoring. Then, signal processing techniques are used for signal pre-processing and analysis to check the condition of the idler. It has been found that even if the damage signature is identifiable in the captured signal, it is hard to automatically detect the fault in some cases due to sound disturbances caused by contact of the belt joint and idler coating. Classical techniques based on impulsiveness may fail in such a case, moreover, they indicate damage even if idlers are in good condition. The application of the inspection robot can “replace” the classical measurement done by maintenance staff, which can improve the safety during the inspection. In this paper, the authors show that damage detection in bearings installed in belt conveyor idlers using acoustic signals is possible, even in the presence of a significant amount of background noise. Influence of the sound disturbance due to the belt joint can be minimized by appropriate signal processing methods.

Suggested Citation

  • Hamid Shiri & Jacek Wodecki & Bartłomiej Ziętek & Radosław Zimroz, 2021. "Inspection Robotic UGV Platform and the Procedure for an Acoustic Signal-Based Fault Detection in Belt Conveyor Idler," Energies, MDPI, vol. 14(22), pages 1-17, November.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:22:p:7646-:d:679952
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    References listed on IDEAS

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    1. Dawid Szurgacz & Sergey Zhironkin & Stefan Vöth & Jiří Pokorný & A.J.S. (Sam) Spearing & Michal Cehlár & Marta Stempniak & Leszek Sobik, 2021. "Thermal Imaging Study to Determine the Operational Condition of a Conveyor Belt Drive System Structure," Energies, MDPI, vol. 14(11), pages 1-18, June.
    2. Piotr Kulinowski & Piotr Kasza & Jacek Zarzycki, 2021. "Influence of Design Parameters of Idler Bearing Units on the Energy Consumption of a Belt Conveyor," Sustainability, MDPI, vol. 13(1), pages 1-13, January.
    3. Yi Liu & Changyun Miao & Xianguo Li & Guowei Xu & Hang Su, 2021. "Research on Deviation Detection of Belt Conveyor Based on Inspection Robot and Deep Learning," Complexity, Hindawi, vol. 2021, pages 1-15, February.
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    Cited by:

    1. Mirosław Bajda & Monika Hardygóra & Daniela Marasová, 2022. "Energy Efficiency of Conveyor Belts in Raw Materials Industry," Energies, MDPI, vol. 15(9), pages 1-6, April.
    2. Karol Semrád & Katarína Draganová, 2023. "Implementation of Magnetic Markers for the Diagnostics of Conveyor Belt Transportation Systems," Sustainability, MDPI, vol. 15(11), pages 1-17, May.
    3. Karol Semrád & Katarína Draganová, 2022. "Non-Destructive Testing of Pipe Conveyor Belts Using Glass-Coated Magnetic Microwires," Sustainability, MDPI, vol. 14(14), pages 1-15, July.
    4. Paweł Bogacz & Łukasz Cieślik & Dawid Osowski & Paweł Kochaj, 2022. "Analysis of the Scope for Reducing the Level of Energy Consumption of Crew Transport in an Underground Mining Plant Using a Conveyor Belt System Mining Plant," Energies, MDPI, vol. 15(20), pages 1-16, October.

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