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The Use of Magnetic Sensors in Monitoring the Condition of the Core in Steel
Cord Conveyor Belts – Tests of the Measuring Probe and the Design of the
DiagBelt System

Article  in  Measurement · March 2018

DOI: 10.1016/j.measurement.2018.03.051

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 Measurement 123 (2018) 48–53

Contents lists available at ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

The use of magnetic sensors in monitoring the condition of the core in steel T
cord conveyor belts – Tests of the measuring probe and the design of the
DiagBelt system
⁎ ⁎
Ryszard Błażeja, Leszek Jurdziakb, Tomasz Kozłowskia, , Agata Kirjanówb,
a
Machinery Systems Division, Wroclaw University of Science and Technology, Poland
b
Economics of Industry and Geoeconomics Division, Wroclaw University of Science and Technology, Poland

A R T I C LE I N FO A B S T R A C T

Keywords: The DiagBelt system for monitoring the technical condition of conveyor belts comprises five modules: a vision
Conveyor belt module, a magnetic module, a prediction module, a rip detection (prevention) module, and a safety factor
NDT method module. This article focuses on the magnetic module, which consists of the BeltGuardTM measuring probe and
Non-destructive testing the DiagBelt application, the latter being used to process the digital signal produced by changing magnetic field
Diagnosis
generated around defects in the magnetized steel cord. Owing to the high resolution of the multi-coil measuring
Belt damage
probe, it is possible to detect not only cuts of individual cords but also broken wires in the cords, and even the
Magnetic method automatic detection
corrosion of cords in the core. The application automatically and precisely detects the location of defects along
the belt axis and on the belt section (due to the position of the coil which traces the changes in the magnetic
field). It also detects the location of all splices in the belt loop. This function allows the changes to be visualized
as a 2D image of belt core defects on all belt sections and splices. The system automatically divides the belt into
sections and counts the defects and their surface area, thus offering useful damage measurement units such as
damage density or damage surface area per 1 running meter of belt. These in turn serve as the basis for a color-
coded image showing the condition of belt loop sections in the DiagBelt system. Such comprehensive diagnostics
of conveyor belts and their splices reduces the number of unexpected failures and facilitates the planning of
maintenance works and of belt replacement procedures, thus contributing to improved conveyor belt manage-
ment.

1. Introduction avoid both emergency downtime and maintenance downtime of belt

Belt conveyors are vital and commonly used elements of transpor-
tation systems in both underground and surface mines. Conveyor belt is
the most expensive part of any belt conveyor. It is responsible for
40–60% of the conveyor’s total price. During operation, the belt may
suffer from adverse phenomena, which may significantly reduce its life-
time. In fact, even if unplanned downtime caused by belt conveyor
damage is short, the company may suffer from huge financial losses.
The loss is caused not only by the need to purchase a new belt, but also
by the interruption of mining production and by bringing the whole
technological process to a halt.
Timely information about damage and the ability to appropriately
interpret the data allows to control undesirable changes (warning
threshold) or take steps before failure occurs (alarm threshold).
Introducing automatic diagnostic systems in mining plants helps to
conveyors.
Monitoring and inspecting technical condition of machines and
devices has become a dynamically growing area of research, with
special attention being devoted to non-destructive testing (NDT)
methods. The greatest advantage of this type of testing lies in the fact
that neither the strength nor the structure of the tested object are af-
fected. NDT methods are successfully employed in many areas. They are
used both in simple systems with single vision cameras, thermal vision
cameras, distance sensors (laser, ultrasound, etc.) and in more complex
systems. The number and type of sensors depends on a number of
factors, the most important of which include inter alia user require-
ments, the type of inspected object, its operating characteristics and the
system’s working conditions etc. Using NDT to correctly recognize
phenomena allows a partial or complete automation of industrial pro-
cesses.

⁎
Corresponding authors.
E-mail addresses: ryszard.blazej@pwr.edu.pl (R. Błażej), leszek.jurdziak@pwr.edu.pl (L. Jurdziak), t.kozlowski@pwr.edu.pl (T. Kozłowski),
agata.kirjanow@pwr.edu.pl (A. Kirjanów).

https://doi.org/10.1016/j.measurement.2018.03.051
Received 29 September 2017; Received in revised form 9 February 2018; Accepted 20 March 2018
Available online 21 March 2018
0263-2241/ © 2018 Published by Elsevier Ltd.
R. Błażej et al. Measurement 123 (2018) 48–53

in one cord, identify its location on the belt and measure its length and
width (Fig. 6).
This article offers a detailed presentation of the DiagBelt magnetic
system intended for inspections of conveyor belts with steel cords. The
system has been developed in the Machinery Systems Division at
Wroclaw University of Science and Technology. It is the result of re-
search performed for many years, as described in earlier works [15–17].

2. Measuring system and raw data

Fig. 1. Change of magnetic field generated by damaged steel cords in the core.
The main component of the DiagBelt system (www.diagbelt.p-
wr.edu.pl) consists of the BeltGuard measuring probe manufactured by
NDT-based methods have been also recently introduced in mining
BeltScan Pty Ltd. from Australia. It enables inspections of conveyor
industry. They are successfully used in the diagnostics of the technical
belts up to 3 m in width and ensures high measurement resolution –
condition of belt conveyors. Earlier research in this area focused on
25 mm. The measuring probe comprises seven modules, each having 16
individual elements of the conveyor: conveyor belts [1–10], drives
coils – a total of 112 coils. The coils allow bipolar measurements.
[12], idlers [11], gearboxes [13,14].
Measurement signals from induction coils are amplified and sent to a
Early in 1979, the CSIRO Division of Applied Physics at Lindfield in
recorder. Coil sensitivity and measurement frequency are set by the
Sydney, under the direction of Alex Harrison, began work on a project
user. A single module is represented in Fig. 3.
called Conveyor Belt Monitor. It was designed to measure the steel mass
High measurement resolution is necessary to identify the number of
present in steel reinforced conveyor belts. In November of that year, the
damaged cords and their location in the belt loop. Some of the pre-
first licence was issued by CSIRO for commercial development of the
viously developed systems detect damage by aggregating changes of
device [1]. The method consists in recording the changes of magnetic
magnetic field from the belt strip 400 mm in width. This fact renders
field in magnetized steel cords of the belt core. The changes of magnetic
the application of such systems impractical, since the belt loop needs to
field are generated by damaged (broken, corroded) or missing cords
be rolled a number of times (e.g. 6 times in the case of a belt having
and by splices of belt sections (Fig. 1).
thickness of 2250 mm) or a number of probes must be used in one
Since that time many various systems have been developed world-
device, thus increasing the cost of the system. Additionally, due to such
wide to detect damage in steel-cord cores [2,8], while the method itself
a low resolution (data are aggregated from a wide strip), interpreting
remained unaltered. Unfortunately, until recently, measurements could
the resulting signal is difficult, since the user is not able to determine
be performed only using measuring probes which aggregated data by
whether the recorded impulse was generated by a single defect of
scanning a width of 40 cm and recorded them in the form of a single
several cords or by multiple minor defects of individual cords located in
measurement channel. This approach does not allow the user to identify
the area. Also, low resolution does not allow the condition of splices to
a single defect, which has to be found by visual inspection (Fig. 2).
be properly evaluated. The resolution offered by the BeltGuard probe
The analysis of a single signal of magnetic field change aggregated
allows not only the representation of defects in the form of 2D images
for a wide measurement track is not easy and requires specialized
but also the estimation of their number and surface area, which are
preparation. The increase in density of the sensors and the narrowing of
convenient measures of belt wear degree.
the measurement tracks does not make interpretation easier, because
The data from the measuring probe and from the tachometer are
belt users still need to observe the individual shape changes of the
sent to the data acquisition module, which then sends them in a digital
signals to deduce something about the nature of the damage [15,17].
format to a mobile computer. Algorithms used in the processing of data
Only a very high density of sensors and a change in the way of imaging
obtained from the magnetic system have been described in [18,19].
from one-dimensional signals to a 2D digital image (presented for the
Before the measurements are performed, the user can adjust measure-
first time in “BELT C.A.T.™” MDR system in 1996 [3]) allowed better
ment sensitivity by setting any data record threshold [mV]. Values
location of damage on the cross-section and easier interpretation of the
below the threshold are recorded as zeros, while the values above the
damage nature, intensity and its extent.
threshold are recorded as either +1 or −1, depending on the magnetic
Owing to the DiagBelt system, it is possible to detect a single defect
pole. The threshold value may be set at any level and is selected so as to

Fig. 2. The example scan of the belt segment between splices (14-9A) with 3 measuring tracks and identified failures (80–85) which has to be found by visual
inspection, e.g. event 80 with 9 cut steel cords.

49
R. Błażej et al. Measurement 123 (2018) 48–53

Fig. 3. Module with magnetic coils.

Fig. 4. The measurement system during conveyor belt tests in an underground mine: (a) two magnets which constantly magnetize the core prior to the measurement;
(b) the measuring probe installed above the idler in order to eliminate the influence of belt flexure/vibrationson the results; (c) tachometer; (d) mobile computer with
software and with data acquisition module.

Fig. 5. 2D image of the belt core in the test conveyor as viewed in the Belt Analysis application; (a) threshold set too low – noise; (b) threshold set too high –
undetected small size defects and weak signal from belt splices; (c) correct threshold.

Fig. 6. The development of corrosion in a single cord of the test belt, as imaged in the Belt Analysis application; (a) before corrosion – cord not damaged; (b) 1st stage
of corrosion development; (c) 2nd stage of corrosion development; (d) 3rd stage of corrosion development.

allow for various parameters, including cord diameter, their density,
belt speed and the distance between the measuring probe and the belt,
as well as to correspond to the user’s experience and requirements. At
an excessively low threshold, the generated noise will be caused by belt
movement and not by defects. At an excessively high threshold, on the
other hand, only splices and largest defects will be detected. Fig. 4
shows the system during measurements on a belt conveyor operated in
an underground mine, and Fig. 5 shows the results for different
thresholds obtained from the core of a belt installed on the test con-
veyor. These are raw data represented in the Belt Analysis application
provided by BeltScan. Gray color indicates no damage (0), yellow color
indicates the negative field (−1) and blue color indicates positive field
(+1). The change of magnetic field from negative to positive corre-
sponds to the location where discontinuity in the cord’s structure starts,
and the change from positive to negative indicates the location where
the discontinuity ends. Therefore, the blue area corresponds to the
defective area of the core. Hence, of the compressed digital record, only
positive cells (+1) can be subjected to statistical analysis, since they
represent the surface area of defects.
The measuring probe is mounted to the conveyor over a flat section
of the belt. It is recommended that the probe is located at a contact
point between the belt and the idler. Thus, the distance between the
belt and the probe is kept constant and the influence of flexure/vibra-
tions in the moving belt is eliminated. This phenomenon has a negative
influence on the amplitudes of magnetic field changes.
The measurement system detects not only cut cords and individual
wires in the cords, but also their corrosion. The tests in laboratory
conditions were performed on a belt with fabricated defects (Fig. 5c).

50
R. Błażej et al.
Fig. 7. Corroded cord of the test belt in various stages of corrosion development: (a) 1st stage; (b) 2nd stage; (c) 3rd stage.
The influence of corrosion on the signal generated in the Belt Analysis
application is shown in subsequent figures (Fig. 6).
Fig. 7 shows digital photographs of a corroded cord in various stages
of corrosion development. The corrosion was stimulated by treating the
cord with saturated solution of table salt (NaCl) in water. In order to
accelerate corrosion, prior to final measurement (after 2nd stage of
corrosion development), the cord was treated with a solution of water
and copper(II) sulfate (CuSO4).
The Belt Analysis application enables the data on belt core condition
to be exported to an external ∗.CSV (comma-separated values) file. This
function offers a significant advantage in comparison to other mea-
surement systems and, together with high resolution, was a major
reason behind the selection of this system for further research and de-
velopment.
Since the data on defects could be processed in external applica-
tions, it was possible to develop an original DiagBelt application which
offers improved capabilities and functions to the measurement system.
3. DiagBelt application
The algorithms of the DiagBelt application which convert the digital
data received from the measuring probe include: signal segmentation
aimed at isolating a full belt loop cycle, splice detection and the de-
tection of defect-related pulse changes in the signal’s magnetic field.
Information about the number and the parameters of automatically
detected splices, including the 2D image, allows the user to subjectively
evaluate the quality of splices and their technical condition during
operation on the conveyor. The test results showing the condition of
belt sections are represented in the main window of the application
(Fig. 8). The view of unfolded belt loop with automatically detected belt
sections occupies the central part of the window. The colors of in-
dividual belt sections correspond to the number of defects per 1 running
Fig. 8. The view of the magnetic module’s main window with a graphic representation of the degree of wear and tear for the segments in the belt loop.
51
Measurement 123 (2018) 48–53
meter of the belt section (i.e. to the damage density), as identified
during the inspection of the belt loop. The user is able to measure the
size of a single defect and to automatically count the number of defects.
Quantifying defects and comparing data from various measurement
periods gives the possibility to use statistical methods and exporting the
data to a text file allows analyses along the belt axis (length) and over
its cross-section (width). Threshold values set by the user allow dis-
tinguishing five degrees of belt wear: no wear, minor wear, average
wear, wear requiring repair/replacement during planned downtime,
wear requiring immediate replacement. These values are represented
on the right hand side of the window, above the loop. Such graphical
representation of the results enables quick estimation of an actual
condition of the belt (its individual sections) operated on the conveyor
and provides grounds for making decisions on further action.
First measurements were performed on a test conveyor, while sub-
sequent tests covered different types of belts operated in real conditions
in both underground and open cast mines. By manipulating the
thresholds, it was possible to adjust the measurement system to the
technical specification of a given conveyor (speed, belt width,
strength). Fig. 9 above shows a fragment of a report from tests per-
formed in an underground mine. It includes a number of basic technical
details about the measurement as well as the results of tests represented
in graphical form and in tables.
The defects may be represented along the belt axis in the form of a
damage density histogram, i.e. the number of defects per 1 running
meter of belt (Fig. 10). By comparing the frequency, it is possible to
view relative differences in the rate of core damage in various locations
on the cross-section, while the number of defects per 1 running meter
allows the comparison of different belt fragments with each other.
R. Błażej et al.
Fig. 9. A page from a report generated by DiagBelt.
4. Conclusions
This paper presents the operating principle of the DiagBelt system’s
magnetic module, which is used to evaluate the condition of steel-cord
belts installed on conveyors and to plan their repair and replacement.
The system facilitates optimal belt management. Potential users of the
system may include both operators of steel-cord belt conveyors (e.g.
ports, smelters, manufacturers of fertilizers, open pit and underground
mines etc.) and external service companies which perform splices, re-
pairs and replacements of conveyor belts. An increasing number of
companies outsource such services. In Polish brown coal mining in-
dustry, according to a commonly employed policy, belts are replaced
preventively to ensure they can be regenerated. Belts are replaced after
a failure or when their condition allows regeneration, i.e. milling the
rubber covers, repairing the core and vulcanizing the covers and the
edges. The DiagBelt system may aid decisions to disassemble worn belts
for regeneration or for scrapping. The system may also be used to in-
dicate excessively worn belt sections which need replacement or repair.
It can also be adjusted to individual belt replacement policies im-
plemented by the users, and – when used regularly – it should prevent a
Fig. 10. Damage density histogram (number of defects per 1 running meter of belt) for the whole loop (above) or for onen of its fragments (complete section between
splices, fragment of a section).
52
Measurement 123 (2018) 48–53
significant number of failures.
The DiagBelt system neither detects nor prevents sudden cata-
strophic failures (rips, punctures or complete immobilization).
However, it allows the user to identify cumulative defects (separating
splices, accumulated cuts of multiple cords in one location or their
corrosion over a large area). Such defects reduce belt strength in its
cross-section and with the passage of time may lead to belt dis-
continuation. Information about such defects are sent to the safety
factor module, which generates appropriate alarms, based on adaptive
interpretation of damage intensity in relation to maximum loads ob-
served on a conveyor. The data generated during subsequent belt scans
are sent to the prediction module, whose function is to determine the
belt’s remaining life. The role of the rip detection (prevention) module
is to raise an alarm and limit the scope of damage by working in
communication with additional mechatronic devices. Such compre-
hensive diagnostics of conveyor belts and their splices reduces the
number of unexpected failures (and the related downtime of transpor-
tation routes) and facilitates the planning of maintenance works and of
belt replacement procedures, thus contributing to improved conveyor
belt management. The choice of an appropriate moment for belt
R. Błażej et al.
replacement or repair allows extended belt life and translates into sig-
nificant financial savings, since belts constitute approx. 40% of in-
vestment and operational costs in belt conveyor systems. Therefore,
investments in the diagnostics and management of conveyor belts are
strongly recommended.
System DiagBelt is a prototype which is used to provide services to
the underground and surface mines. The aim of this services provided
by university personnel, however, is not profit generation but gathering
data for its further development. There are several scientific aims which
has to be attained. Among them few are important for further devel-
opment of the system and its forecasting strength:
1. Identification of remaining belt life based on their current condition
(evaluated by DiagBelt scans) and determination of non-linear rate
of damage accrual [20]. With the wear of belt covers the belt core is
more and more sensitive to damage. Loaded lumps of material need
less and less energy to break through the rubber and damage the
steel cords.
2. Identification of the rate of increasing damage in the x and y di-
rection. High resolution of the DiagBelt scanner allows on detail
observation of single failures. Subsequent observations allow on
identification of damage increase. One interesting observation
which seems to be contrary to the expectations is that the corrosion
of the cable also develops across the belt and not just along the steel
cords. Apparently, the cracking of the rubber in the area of the
damage spreads across the belt due to the numerous bending of the
belt on the drums and rollers and the water begins to reach the
adjacent lines.
3. Automatic evaluation of steel cord belt splices quality. Belt segments
splices in the loop is the weakest link. Over time, the strength of
splices due to fatigue processes decreases and the joints themselves
can be subject to many punctures and corrosion. The magnetic
image of the joint and its changes over time can say a lot about its
quality and strength, which is why this direction of research is
continued [10].
4. Conditional operational safety of steel-cord conveyor belts. The
consequences of damage to the core of the belt depend on the
stresses occurring in it. These, in turn, depend on the conveyor's
construction and the resistance of motion that occurs on it. The le-
vels of alerts cannot, therefore, depend on the size of the damage,
but on the ratio of weakness to the maximum stresses in the belt.
Currently, conditional safety indicators for belts are being devel-
oped [21,22].
If mines or conveyor belt service companies were interested, the
developed system could be widely implemented in Polish mining in-
dustry as well as in harbors and metallurgy or chemical plants. There
are over 2000 km of belts installed in Poland. Majority of belts used in
lignite mines (over 500 km) are steel cord belts, which can be scanned
using DiagBelt system. Of course conveyor belts are used not only in
Poland but here level of implementation of such systems is still very
low.
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