Escaner Electromagnético de Faja Transportadora-Steel SPECT

SteelSPECT User Manual
Page 1
Thank you for purchasing SteelSPECT.

This guide describes the steps to using the SteelSPECT.
We strongly recommend reading this manual carefully before using SteelSPECT.
For technical support, inquiries and related matters, please contact us:
Rampart Detection Systems Ltd.

203 – 22242 48th Avenue
Murrayville, British Columbia,
V3A 3N5
Canada
Tel: +1 - 604 - 533 - 5533
Fax: +1 - 604 – 533 - 5543
info@rampartdetection.com
This manual is Copyright Rampart Detection Systems Ltd 2019
Page 2
Safety Warnings
!!!WARNING!!!
Working near conveyor belts is
DANGEROUS!
Ensure safety precautions have been taken before beginning work.
Follow safety procedures
!!!WARNING!!!
Very Strong Magnetic Fields!

Persons with medical implants stay clear.
Keep metal objects away from Scanner.
!!!WARNING!!!
Heavy object!
Multi-person lift required.
Page 3
Contents
Title............................................................................................................................................................1
Introduction..............................................................................................................................................2
Safety Warnings.......................................................................................................................................3
Contents....................................................................................................................................................4
What is SteelSPECT?..............................................................................................................................5
Technical specifications...........................................................................................................................6
Suggested scanning protocol..................................................................................................................7
Unboxing...................................................................................................................................................8
How to assemble SteelSPECT.................................................................................................................9
First tests of assembled SteelSPECT....................................................................................................13
Mounting.................................................................................................................................................14
How to Scan............................................................................................................................................17
Processsing a scan..................................................................................................................................28
View belt..................................................................................................................................................29
Generate report......................................................................................................................................30
File and directory layout.......................................................................................................................39
Interpreting cable damage....................................................................................................................42
Wringer settings.....................................................................................................................................53
Report page layout.................................................................................................................................74
Questions and answers..........................................................................................................................76
The care and feeding of steel cord conveyor belts...............................................................................83
Page 4
What is SteelSPECT?
SteelSPECT is a tool that is used to magnetically image the steel cords in a steel cord conveyor belt. By
measuring variations in the magnetic fields conveyed by the steel cords, damage and splices can be
identified.
A typical SteelSPECT system is comprised of a computer, used to record and process scan data, a
power/communications cable(power/comms) and a scanner, either modular(comprised of two to four
modules) or singular. A modular system is typically used in a portable scan-as-a-service capacity while
a singular unit is typically used in a permanent installation setting. The Modular and Singular
SteelSPECT scanner heads perform exactly the same funtion with the only difference being that the
Modular system can be dissasmbled for ease of portability. A permenantly installed computer with
armoured cable is also available.
The software used to collect the scan data and process it is called Wringer. Wringer allows for viewing
of the scan data and report generation.
Page 5
Technical Specifications
Scanner head power consumption:

- 15W per module or per 610mm
- Four module unit consumes about 60W
Computer/Laptop requirements:
- Intel i5 or i7 with 8GB RAM or better
- Ubuntu 14.04 or 16.04
A modular scanner consists of a head module, where the power/communications cable is connected to,
a tail module and middle modules.
The smallest scanner that can be assembled consists of the head and tail modules. Middle modules can
be added inbetween the head and tail modules to widen the scanner. A maximum of two middle
modules can be used. If you need a scanner wider than 2440mm, please contact your SteelSPECT
supplier.
A single module is 610mm wide. A scanner can come in the following widths: 1220mm, 1830mm and
2440mm.
Operating temperature range about -40 to +80 Celcius.
Scanning rate is 1074 samples per second. For example, a belt traveling at 5m/s(meters per second) will
have a sample or reading at (5 meter per second divided by 1074 samples second equals)
4.66millimeters. The entire conveyor belt is sampled at 4.66millimeter intervals.
The sensor density of the SteelSPECT scanner is one sensor every 6.35mm. A single module contains
96 sensors. Across a four module scanner this equals 384 sensors.
Page 6
Suggested Scanning Protocol
Check list
1 x SteelSPECT scanner(modular or singular)
1 x Power/Communications cable
1 x Computer(Laptop)
Scanning Steps
#1. Assemble SteelSPECT scanner if required.

#2. Connect Power/Comms cable to computer and SteelSPECT scanner.
#3. Power up Scanner.
#4. Start up computer.
#5. Start Wringer.
#6. Create Client and add Conveyor.
#7. Perform quick test scan to ensure proper functioning. A seperate Client/Conveyor can be created for
this function.
#8. Install Scanner.
#9. Perform scan.
Page 7
Unboxing
Upon receiveing crate, you will need a robertson head screw driver. If the crate is a long rectangle, this
means the Units are pre-assembled and you may test the system immediately.
If the crate is a cube, the modules have been seperated and require assembly.
Illustration 1: Unpacking modular SteelSPECT

Page 8
How to assemble SteelSPECT

 Take out of box in pieces.
 Lay on a flat operating surface if possible.
 Using a 6mm hex, loosen the 4 screws for the Aluminium connecting rods.
 Starting from head module insert Aluminium connecting rods into receiving module.
 Insert modules to 1 cm apart.
 Hand tighten screws on hook plates using 6mm hex this will correctly align the modules.
 Engage
latches and
carefully
lock into
place.
Page 9
Illustration 2: Unpacking SteelSPECT and Head Module

Illustration 3: SteelSPECT module assembly
Page 10
Illustration 4: SteelSPECT latch
Page 11
Illustration 5: SteelSPECT latch closed
Page 12
First test of assembled SteelSPECT

Once the SteelSPECT is mechanically assembled, the power cable can be brought in.
 Insert the cannon connector to the BG Unit making sure to match the tooth and groove.
 Connect Ethernet cable to processing Unit.
 Plug in power cable.
Illustration 6: Power and communications cable connection to SteelSPECT
Illustration 7: Power/communications connection to SteelSPECT
Page 13
Mounting
Finding a suitable scanning location

SteelSPECT mounting location requirements**:
Before starting the installation process, find a suitable place along the conveyor belt.
Characteristics of the optimal mounting position include:

 Minimal conveyor belt flutter
 Return side of the belt
 Within 2.5cm or less of the belt
 Mounted perpendicular to belt
 Minimal risk of being struck by foreign objects
 A suitable place for the control box to be mounted within 3m of SteelSPECT scanning head
 Between idlers spaced 61cm to 71cm apart
List of personnel required:

 Welder
 Electrician
 Labourer(s) to assist in lifting and mounting the Beltgard scanning head
 IT or networking personnel to perform DHCP configuration, networking
and setup
Power Requirements:
 100-277VAC 50/60Hz, 15 Amp
Networking Requirements***:
 Network access (fibre optic or cat5e depending on site)
* Required when belt is not steady.

** The SteelSPECT scanning head can be mounted in any orientation (left to right or right to left) with
respect
to the belt.
*** The networking requirements may vary by site. Consult your IT department before installation.
how to install BG at scanning location
Page 14
Illustration 8: Ideal Placement of SteelSPECT scanner
Illustration 9: SteelSPECT mounted under conveyor belt.
Page 15
Illustration 10: Power and communications cable connection to SteelSPECT
Illustration 11: Connected Power and communications cable. Click is heard when
locked.
Page 16
How to scan
Illustration 12: SteelSPECT Mobile Scanning Interface Launch Icon
Step #1. Find the SteelSPECT icon and click it. This will launch the SteelSPECT interface as seen in
Illustration 12.
Page 17
Illustration 13: SteelSPECT New Icon
Step #2. Begin by clicking on the new icon as seen in Illustration 13.
Page 18
Illustration 14: New Client Dialogue Box
Step #3. Select client in the drop down menu as seen in Illustration 14.
Page 19
Illustration 15: Client Name and Path to Client Logo
Step #4. Enter the clients name in the dialogue box. If you have a copy of the clients logo on your
computer, the path to the image can be entered into the client logo field as seen in Illustration 15. Click
Ok when done.
Page 20
Illustration 16: Client displayed in Interface
Step #5. The clients name is now in the SteelSPECT Mobile Scanning Interface. Please see Illustration
16.
Page 21
Illustration 17: Conveyor Details
Step #6. Right click on the clients name in the SteelSPECT Interface you wish to add a conveyor belt
to. A dialogue box will appear. Enter the details of the conveyor belt into the fields in the dialogue box
as seen in Illustration 17.
The most important fields in this dialogue box that need to be entered correctly are:
• Belt Speed
• Belt Length
• Belt Width
• Number of Cables in Belt
• Number of Scanner Modules
Please see Wringer Settings for details.
Page 22
Illustration 18: SteelSPECT interface with Client and Conveyor
Step #7. Right click on the conveyor that you wish to scan. Notice that the Scan Button becomes
active.
Page 23
Illustration 19: SteelSPECT ready to Scan
Step #8. When you are ready, click the Scan Button.
Page 24
Illustration 20: Pre Scan Settings
Step #9. After the Scan Button is pressed, this dialogue will pop up.
Pressing the Ok button will begin the scan.
The PXR Threshold and RG Threshold values are set to 2 by default. These values can be changed after
if required. Setting the number higher removes details from the image. Setting the number lower add
details to the image. (Note by the Author: I set these values to 0 so I can see the images at the highest
level of detail)
See Illustration 20.
Page 25
Illustration 21: Connection Established and Connecting to SteelSPECT
Step #10. Once the scan has begun, a progress bar will appear at the bottom with a activity icon and
timer. The Connection Established, You are now connected to SteelSPECT notification should appear
and may appear from time to time if the SteelSPECT scanner is powered up and connected to the
computer. See Illustration 21.
Please note, pressing the Cancel button at any time during the scan will stop the scan and remove
any data received.
Page 26
Illustration 22: Scan is complete.
Step #11. Scan is complete. Notice that the progress bar has fully moved from left to right, the pop up
dialogue box displays Scan for Conveyorbelt Complete and that a small black triangle has appeared
next to the Conveyorbelt in the Client/Conveyor field.
Page 27
Processing a scan
Illustration 23: Processing a scan
Step #1. Click on the black triangle to expose the latest scan. Left click on the scan you want to
process. Notice that the Generate a Report and View Belt buttons have become active.
Generate Report will create a PDF document. The progress bar will appear. Once the processing has
completed, the PDF should open and appear for the user.
View Belt will generate a series of images for viewing. The progress bar will appear. Once all the
images have been generated, a dialogue box allowing navigation of the images will pop up.
Page 28
View belt
Illustration 24: View Belt viewer
In Illustration 24 the Belt Viewer window is displayed. Using the slider near the top of the window or
arrow keys, the user can navigate the belt. At the top right of the window, Red Green can be selected or
Pseudo x-ray can be selected in the drop down menu.
Page 29
Generate report
Illustration 25: Report Generation Settings
In Illustration 25, after pressing the Generate Report button, a dialogue box allowing the user to edit the
report by clicking on Edit Report appears. Under Fault Display, the user is able to select All Faults,
Only Splices, Splices and Major Faults and No Faults(Will display Splices only)
Page 30
Illustration 26: Report Edit
In Illustration 26 a short list of three faults are shown. By clicking the check mark, the user can select
or de-select what faults appear in the report. Once complete, click OK. This will return the user to the
Report Generation Settings as seen in Illustration 25. Clicking Generate will generate a report based on
the users settings. Once the report has been generated, it should appear to the user automatically.
Page 31
Illustration 27: Report Cover Page
Illustration 27 shows the Report Cover Page. The text on the cover page and images can be defined by
the user.
Page 32
Illustration 28: Report Table of Contents
Illustration 28 is the Report Table of Contents. This page is automatically generated by the SteelSPECT
software(wringer).
Page 33
Illustration 29: Report Summary
Illustration 29 shows a summary generated by the software for the report.
Page 34
Illustration 30: Report Mini Map
The Scan Summary as seen in Illustration 30 shows three faults.
Page 35
Illustration 31: Report Fault
Page 36
Page 37
Page 38
File and Directory Layout
This section details the files and directories used by the SteelSPECT software.
Illustration 34: Yellow arrow points to file

browser
Illustration 35 shows a yellow arrow pointing at the file browser. Click on this icon to begin viewing
files.
Page 39
Illustration 36: Yellow arrows pointing at Desktop and Scans
Illustration 36 shows a yellow arrow pointing a the Desktop directory and a yellow arrow pointing at
the Scans directory. Click on Desktop first. Then double-click on Scans. You should now see two
directories listed, data and report.
Double-clicking on the data directory will show all of the Clients.
Double-clicking on a particular Client will list the Conveyor belts.
Double-clicking on a particular Conveyor belt will list the scans that have been taken.
Page 40
data
Client Client
Conveyor Conveyor Conveyor Conveyor Conveyor
Scan Scan Scan Scan Scan Scan Scan Scan Scan Scan
Illustration 37 data directory layout
Illustration 37 describes the heirarchy of the data directory structure.
Scan directories have numbers for their names. The number is a linux time stamp. In the file browser
window, pressing ctrl + 1 simultaneously will change the way the files and directories are listed. In this
way it is easier to see when a directory or file was created.
The report directory follows a similar layout. In the last directory resides the report, which should be
opened automatically by the SteelSPECT software once Generate Report has finished, and a csv file
listing what was found along with a few details.
Page 41
Interpreting cable damage
Illustration 38: Four Step Splice in Red Green Viewing Mode
Illustration 39: Four Step Splice in Pseudo X-ray Viewing Mode
Illustration 38 and Illustration 39 show the same Four Step splice.
Observations by the Author.

This Four step splice appears to have some damage on the first three bias angles (splices) from left to
right. The quality of the scan could be improved by moving the scanner a bit closer to the belt or
allowing a longer belt conditioning time. A visual inspection of this splice is suggested as well as
regular scanning of this belt in order to monitor the health of this splice.
Page 42
Illustration 40: Fault in Red Green
Illustration 41: Fault in Pseudo X-Ray
Illustration 40 and Illustration 41 show the same fault. Faults come in various sizes and shapes and this
is what a typical fault looks like. The arrangment of the red/green grey/white within the fault is not of
particular importance.
Page 43
Illustration 42: Four Step Splice with faults in Red Green
Illustration 43: Four Step Splice with Faults in Pseudo X-Ray
Illustration 42 and Illustration 43 show the same Four Step Splice.

Please notice the fault in the Fourth bias angle(From Left to Right) and in the upper part of the First
bias angle(from Left to Right). Notice the Faults after the splice. There are also a series of faults to the
right of the Splice. A visual inspection of this splice should be performed as soon as possible. Aside
from the faults, the bias angles look good. There may be uneven wear along the middle of the conveyor
belt. Notice the bottom edges of the splice. They bear resemblance to faults but most likely are not.
Deformation at the edges of splices and faults can occur at the sides of the conveyor belt. The threshold
for red/green(rg) and pseudo x-ray(pxr) are 0.
Page 44
Illustration 44: Clean Conveyor Belt in Red Green
Illustration 45: Clean Conveyor Belt in Pseudo X-Ray
In Illustrations 36 and 37, a clean belt is shown. What is seen in these images represents noise. The
threshold values are set to 0. Red Green and Pseudo X-Ray show the same data processed by different
methods.
Page 45
Illustration 46: Close up Red Green
In Illustration 38 a close up of a conveyor belt seen in Red Green mode is displayed. Please note the
high lighted area. The high lighted area represents the conveyor belt itself.
Page 46
Illustration 47: Arrows describing the

distance between scanner and belt edge
In Illustration 47, the two yellow arrows describe the distance between the first sensor(upper arrow) in
the scanner and the edge of the belt(lower arrow). This distance can be defined in the Advanced
settings dialogue under belt_scanner_offset.
Page 47
Illustration 48: Arrows describing belt

width
In Illustration 48, the yellow arrows describe the belt width. This distance can be defined in the
Advanced settings dialogue under belt_width.
Page 48
Illustration 49: Left over edge

Illustration 49 describes the distance between the edge of the conveyor belt(upper arrow) and last
sensor of the SteelSPECT scanner(lower arrow). This distance cannot be set by the user.
Page 49
Illustration 50: Arrows describing

SteelSPECT scanner width
Illustration 50 describes the distance between the first sensor (upper arrow) and last sensor (lower
arrow). This is described by the number of modules.
Page 50
Illustration 51: Conveyor Belt Zone

Layout
Illustration 51 describes the various zones of the conveyor belt as seen by the SteelSPECT
software(wringer). Zones 1 and 3 are outside of belt. Zone 2 highlights the belt area.
Please see ‘out_side_of_ .....’ under WRINGER SETTINGS.
Page 51
Illustration 52: Cable ends? (Image in Red/Green)
Illustration 53: Cable ends? (Image in Pseudo X-ray)
Illustration 52 and Illustration 53 was processed with filter_x_frequency set to 60.

By setting filter_x_frequency to 60 it is believed that the individual cables ends can be seen. We have
counted the individual dots along the Y-Axis and they added up to the correct number of cables. The
issue that arrises with setting the filter_x_frequency to 60 is that the data becomes fainter and more
difficult for the software to discern.
Page 52
Wringer settings
IMPORTANT: To make the new values take effect, quickly select a different scan and process it in
View Belt mode. Press Cancel as soon as the processing has begun. Go back to what you were working
on. We know this isn’t ideal.
List of settings used by the SteelSPECT processing software.

Units do not need to be added. Example: 1 not 1m
These settings are found by right-clicking on the Conveyorbelt entry you wish to change,
left-clicking on Edit then left-clicking on the Advanced button.
belt_length
Description: This is the known length of the conveyor belt in meters entered by the user.
Example: 1000
Range: 0 – 99999
Unit: meter
Explaination: This is where the length of the conveyor belt is recableed. The measurement is in
meters. The length is load and return sides added. This value is used to calculate the scan time.
belt_scanner_offset
Description: Where does the belt lie on the beltgard? This is the offset value between where the first
sensor on the beltgard is and the conveyor belt edge. This measurement is in meters.
Example: 0.375
Range: 0.0 – 3
Unit: meter
Explaination: When the scanner is placed under the conveyor belt, what is the distance between the
edge of the conveyor belt and the connection edge of the scanner?
Page 53
belt_speed
Description: What is the speed of the belt?
Example: 5
Range: 0 – 100
Unit: meters per second
Explaination: What is the speed of the belt in meters per second? This value is used to calculate the
scan time.
belt_supplier
Description: What is the name of the belt supplier?
Example: <Belt supplier name>
Explaination: This field is optional. If you know the supplier of the belt, you can enter it here.
belt_width
Description: Width of the belt in meters.
Example: 1.5
Unit: meter
Explaination: Enter the width of the conveyor belt here. This value is used in processeing. This value
is also used when highlighting the belt in the image and used in conjunction with
out_side_of_belt_action and out_side_of_belt_color. Please see out_side_of_belt_action and
out_side_of_belt_color.
beltname
Description: What is the name of the belt?
Example: <Your_belt_description_here>
Explaination: What is the name of the conveyor belt?
bias_angle_distance
Description: Distance between bias angles for clumping. Distance in meters.
Example: 2.0
Default: 2.0
Unit: meter
Explaination: Individual splices with in this distance of each other are combined into a splice.
Page 54
blur_times
Description: Number of times the blur algorithm is to be called for monochrome detection.
Example: 10
Default: 10
Explaination: This value is used by wringer when processing a scan file. Clusters are enlarged by this
value.
NOTE: DO NOT CHANGE
bylogo
Description: The bylogo
Explaination: <Enter the path to the bylogo image>
byname
Description: Enter the byname
Explaination: <Enter the value of the byname here>
cables_in_the_belt
Description: How many steel cables in the belt?
Example: 100
Range: 0 - 1000
Explaination: How many steel cables are in the conveyor belt? This value is used to compute the
number of steel cables affected by a fault.
Page 55
create_intermediate_images
Description: Should wringer create and output the intermediate images of data that is inprogress in
wringer?
Choices:
- true
- false
Default: false
Explaination: This is used for diagnostic purposes and increases processing time.
NOTE: DO NOT CHANGE
csv_path
Description: Where do the csv files generated by wringer go?
Value: csv/
Explaination: This is where a csv file of the conveyor belt is saved.
NOTE: DO NOT CHANGE
decompressed_path
Description: Path to decompressed scan file.
Value: decompressed/
NOTE: DO NOT CHANGE
default_path
Description: Default path for this instance of wringer.
Default: /home/rampart/.rampart/wringer_out/
Explaination: This is an installation specific parameter.
NOTE: DO NOT CHANGE
Page 56
email
Description: What is your email address?
Default: <Enter your@email_address.com here>
Explaination: Enter your email address here.
end_of_belt_color
Description: The color at the end of the belt.
Default: 200, 150, 100
Range: 0-255, 0-255, 0-255
Order: RED, GREEN, BLUE
Explaination: At the end of the very last image, this is the fill color.
NOTE: DO NOT CHANGE
extra_border
Description: Extra distance between fault, hole or splice and the square drawn around it.
Default: 5
Explaination: When the processing software draws rectangles around faults and splices, this is the
distance between the fault or splice and the rectangle.
NOTE: DO NOT CHANGE
fax
Description: What is your fax number?
Default: <Enter your fax number here>
Explaination: Do you still have a fax machine? If you do, you can enter your fax number here.
filter_x
Description: Turn the high pass filter on or off X-AXIS
Default: false
Explaination: Turn on or off a low-pass filter along the x-axis.
Page 57
filter_x_frequency
Description: The cut off frequency in Hertz X-AXIS
Default: 30
Range: 0 – 1000
Unit: Hertz
Explaination: This is the cut off frequency for the filter_x setting.
filter_y
Description: Turn the high pass filter on or off Y-AXIS
Default: true
Explaination: Turn on or off a low-pass filter along the y-axis.
filter_y_frequency
Description: The cut off frequency in Hertz on the Y-AXIS
Default: 40
Range: 0 – 1000
Unit: Hertz
Explaination: This is the cut off frequency for the filter_y setting.
fods
Description: Filter Out Defective Sensors. true or false
Default: false
Explaination: Defective sensors can effect the output of the processing software. The typical failure
mode of sensors is to be non responsive. Suggested use of this feature is to set this to true and increase
fods_lower and decrease fods_upper, reprocess the images and repeat until the defective sensor is
removed. It is possible that this method may not work. Typical sensor readings are between 600 and
800. Please contact your dealer for further instructions on this feature.
Page 58
fods_lower
Description: Filter out values below this value if fods is true
Default: 10
Explaination: When fods is set to true, sensor readings below fods_lower are replaced with their
nearest valid neighbour.
Unit: Pixel
fods_upper
Description: Filter out values above this value if fods is true
Default: 1024
Explaination: When fods is set to true, sensor readings above fods_upper are replaced with their
nearest valid neighbour.
forlogo
Description: The forlogo
Default: <Enter your forlogo here>
Explaination: Path to the forlogo.
Please see Report Page Layout
forname
Description: The forname
Default: <Enter your forname here>
Explaination: Enter the forname here.
Page 59
headerlogo
Description: The headerlogo
Default: <Enter your headerlogo here>
Explaination: This image appears at the top left of each page of the report.
ignore_center_cables
Description: Ignore clusters with less than this number of cables broken.
Default: 1
Unit: Cables
Explaination: When a cluster is evaluated by the processing software, clusters/faults found to have this
many or less cables affected are ignored.
ignore_edge_cables
Description: Ignore clusters with less than this number of cables broken.
Default: 1
Explaination: When a cluster is evaluated by the processing software, clusters/faults found to have this
many or less cables affected are ignored.
image_background_color
Description: The background color of the images
Default: 64, 64, 64
Range: 0-255, 0-255, 0-255
Explaination: This is the background color of all the images.
NOTE: DO NOT CHANGE
Page 60
image_scale_color
Description: Color of the scale used in all images
Default: 0, 255, 0
Range: 0-255, 0-255, 0-255
Explaination: This is the color of the distance bars on the top and bottom of the images
NOTE: DO NOT CHANGE
image_sequence_text_color
Description: Color of the text in the bmp and jpg images generated.
Default: 0, 0, 0
Range: 0-255, 0-255, 0-255
Explaination: This is color of the text in the images
NOTE: DO NOT CHANGE
json_pseudo_x_ray_path
Description: Path to the images as set out in the json files.
Default: json_pxr_images/
Explaination: This is the path to json_pxr_images.
NOTE: DO NOT CHANGE
json_rg_original_path
Description: Path to the images as set out in the json files.
Default: json_rg_images/
Explaination: This is the path to json_rg_images.
NOTE: DO NOT CHANGE
Page 61
language
Description: Which language shall be used in the report?
Default: english
Explaination: This is the language selected for report generation.
NOTE: DO NOT CHANGE
length_divisor
Description: To process the file faster, divide the file by this number
Default: 1
Explaination: In some cases, faster processing of the conveyor belt is required, in particular, when the
scan time is very long. The length of the belt is divided by this value and the first fraction of the scan is
processed.
NOTE: DO NOT CHANGE
location
Description: Name of where is this belt located?
value: <Type in description of where the belt is located>
Explaination: This is where the description of where the conveyor belt’s location is entered.
lower_mass_threshold
Description: Faults found with a mass less than this are ignored.
Default: 10
Range: 0 - 1000
Explaination: Clusters comprised of this many or less pixels are omitted from report generation.
NOTE: DO NOT CHANGE
Page 62
majority_matrix_size
Description: Majority matrix x and y size for rg_original and monochrome. Must be odd number.
Default: 5
Range: 1 - 999
Explaination: A filtering algorithm used to remove noise from images. Change with caution.
majority_matrix_skip
Description: Should wringer skip doing majority matrix skip. true = skip, false = don’t skip
Default: false
Explaination: Enable or distable majority matrix filtering. Change with caution.
minimum_splice_width
Description: Minimum splice width along the y-axis. Distance in meters.
Default: 1.0
Range: 0.0 – 3.0
Unit: meter
Explaination: For a cluster to be recognized as a splice or part of splice, it must exceed this width.
minor_center_cables
Description: Clusters between this and ignore are reported as minor faults. Greater than are reported as
major.
Default: 10
Range: 0 - 1000
Explaination: When the processing software attempts to classify clusters it has found, clusters found
between minor_center_cables and ignore_center_cables are reported as minor faults.
minor_edge_cables
Description: Clusters between this and ignore are reported as minor faults. Greater than are reported as
major.
Default: 10
Range: 0 -1000
Explaination: When the processing software attempts to classify clusters it has found, clusters found
between minor_edge_cables and ignore_edge_cables are reported as minor faults.
Page 63
monochrome_cluster_path
Description: Path where monochrome clusters are stored
Default: monochrome_clusters/
Explaination: Path to monochrome_clusters directory.
NOTE: DO NOT CHANGE
monochrome_images_path
Description: Path to where the monochrome images are stored
Default: monochrome_images/
Explaination: Path to monochrome_images_path.
NOTE: DO NOT CHANGE
monochrome_minimum_x_size
Description: Minimum length along the x-axis for monochrome to classify this as a splice. Distance in
meters.
Default: 0.05
Range: 0.0 – 1000.0
Unit: meter
Explaination: When a splice is found, it must exceed this distance.
monochrome_threshold
Description: Monochrome threshold. Should be 1 or greater.
Default: 1
Range: 1 – 1000
Explaination: This is the threshold used for processing data when locating faults and splices.
NOTE: DO NOT CHANGE
Page 64
non_belt_color
Description: Non-belt color
Default: 20, 20, 20
Range: 0-255, 0-255, 0-255
Explatination: This is the color used in the image of the belt that lies outside of the belt as defined by
belt_scanner_offset and belt_width.
number_of_poles_x
Description: Calculate the coefficients with this number of poles X-AXIS
Default: 2
Range: 0 - 1000
Explaination: This defines the order of the filter used on the X-AXIS.
NOTE: DO NOT CHANGE
number_of_poles_y
Description: Calculate the coefficients with this number of poles Y-AXIS
Default: 2
Range: 0 - 1000
Explaination: This defines the order of the filter used on the Y-AXIS.
NOTE: DO NOT CHANGE
number_of_sensors
Description: How many sensors are in the head?
Default: 192
Range: 0 - 1000
Explaination: This value MAY need to be used in some cases. Typically, this value is stored in the
scanfile. This is set when you choose the number of modules.
NOTE: DO NOT CHANGE
Page 65
number_of_threads
Description: How many threads shall be used?
Default: 8
Range: 8 - 1000
Explaination: Wringer, the software used to process scanfiles, is a multithreaded application.
NOTE: DO NOT CHANGE
omit_holes_faults_in_splice
Description: Omit holes and faults from with in the bounds of a splice, true or
false?
Default: true
Explaination: Faults found with in the region of a splice can be omitted.
orgname
Description: The name of your organization/company name
Value: <Enter your orgname here>
original_r_g_path
Description: Path where original Red Green files are put.
Default: rg_original/
Explaination: Path to original_r_g_path.
NOTE: DO NOT CHANGE
Page 66
out_side_of_belt_action
Description: How should belt area outside of the belt width be dealt with?
Default: blend
Choices:
- blend
- over_write
- nothing
Explaination: How should the area of the image that is outside of the belt be rendered? It can be
blended with the belt using the out_side_of_belt_blend_pecentage, over_write and use
out_side_of_belt_color or nothing.
out_side_of_belt_blend_percentage
Description: When blend is selected, this is the percentage blending
Range: 0 - 100
Default: 50
Explaination: The area outside of the belt is darkend by this percentage.
out_side_of_belt_color
Description: Color on image of area outside of the belt as previously defined.
Default: 30, 30, 30
Range: 0-255, 0-255, 0-255
Explaination: What color should the area outside of the belt be?
outer_edge_in_meters
Description: Width of the outer edge in meters.
Default: 0.25
Range: 0.0 – 2.0
Unit: meter
Explaination: The distance from either edge of the belt towards the inside. This is defined as the edge
and different threshold for faults found there can be defined.
Page 67
path_to_build_script_file
Description: Path to report build script
Default: /opt/rampart/report/build.sh
Explaination: Path to report build script.
NOTE: DO NOT CHANGE
phone
Description: The phone number
Value: <Your Phone Number>
Explaination: Enter your phone number here.
projectname
Description: The projectname
Value: <Enter Project Name>
Explaination: Enter the project name here.
pseudo_x_ray_path
Description: Path where pseudo x-ray files are put.
Default: pseudo_x_ray/
Explaination: Path to where pseudo x-ray files are put.
pxr_avg_loop_value
Description: Value to add or subtract to get closer to the average when pxr_sample_limit is arrived at.
Default: 1
Range: 0 - 1000
Explaination: Value to add or subtract to get closer to the average when pxr_sample_limit is arrived at.
NOTE: DO NOT CHANGE
Page 68
pxr_images_path
Description: Path to where the pseudo-x-ray images are stored
Default: pxr_images/
Explaination: Path to where pseudo x-ray files are put.
pxr_sample_limit
Description: Used in simple_threshold. How many overs or unders required to bump the mean up or
down?
Default: 500
Range: 0 - 10000
Explaination: Used in simple_threshold. How many overs or unders required to bump the mean up or
down? Used in the generation of pseudo x-ray images.
pxr_threshold
Description: Pseudo x-ray threshold value
Default: 0
Range: 0 – 1000
Explaination: Pseudo x-ray image threshold. 0 is highest resolution.
rectangle_color
Description: Color of the rectangle that high lights faults and splices.
Default: 255, 153, 10
Range: 0-255, 0-255, 0-255
Explaination: The color of the rectangle drawn around faults and splices. Default is orange.
Page 69
render_faults
Description: In the report, show the summary only or summary and details.
Default: summary_and_faults
Choices:
- summary_only
- summary_and_faults
Explaination: What level of reporting on the current scanfile should be done?
NOTE: DO NOT CHANGE
report_path
Description: Report path
Default: report/
NOTE: DO NOT CHANGE
report_pdf_output_file_path
Description: The full path to the report.
Default: /home/rampart/.rampart/wringer_out/report/report.pdf
report_type
Description: What kind of report should wringer create? <Example:regular> for a report only on what
is in the scan file.
Default: regular
Choices:
- pictures_only
- regular
NOTE: DO NOT CHANGE
rg_images_path
Description: Path to where the red green images are stored.
Default: rg_images/
NOTE: DO NOT CHANGE
Page 70
rg_lag_value
Description: Red Green lag value. Used in generation of Red Green Images.
Default: 20
Range: 0 – 1000
rg_threshold
Description: Red Green threshold value. Set higher to filter stuff out. Set to 0 for maximum resolution.
Default: 2
Range: 0 – 100
sample_rate
Description: Scanning head sample rate.
Default: 1074
NOTE: DO NOT CHANGE
sandbox_sensors_add
Description: Number of sensors to add to either side of a sandboxed matrix
Default: 25
NOTE: DO NOT CHANGE
sandbox_slices_add
Description: Number of slices to add to the front and back of a sandboxed matrix
Default: 1000
NOTE: DO NOT CHANGE
scaling_factor
Description: Scaling factor. Number of cables cut is multiplied by this number to scale depending on
results.
Default: 1.0
Range: 0.0 – 1.0
Authors note: If the number of broken cables in a fault is too high, you can divide the number of
cables reported by the number of cables that should be reported. This number should be less than 1.
Enter this number in this setting.
Page 71
simple_threshold_threaded_weight_of_averaging
Description: Weighted averageing value
Default: 1
Range: 0 - 1000
NOTE: DO NOT CHANGE
splice_rectange_add_x_axis
Description: Add this to the front and back along the x-axis drawing rectangle
Default: 1
Range: 0 - 1000
Unit: m
NOTE: DO NOT CHANGE
square_top_offset
Description: The offset from the top of the picture to where the rectangles are drawn.
Default: 3
NOTE: DO NOT CHANGE
st_rating_of_belt
Description: What is the ST rating of the conveyor belt?
Value: <Enter ST value of belt>
stroke_width
Description: Thickness of the rectangle in pixels
Default: 5
NOTE: DO NOT CHANGE
website
Description: Your website
Value: <Enter your website>
Page 72
wringer_log_path
Description: Database entry for path to wringer log
Default: wringer_log/
NOTE: DO NOT CHANGE
wringer_phrase_path
Description: Path to language configuration file
Default: /opt/rampart/wringer/locale/CA.conf
NOTE: DO NOT CHANGE
Page 73
Report Page Layout
Illustration 54: Report Layout
Illustration 54 describes the relationship between what is seen in a report and the various settings
available in the advanced menu. The GREEN rectangle is image pointed to by the filepath in
BYLOGO. The RED rectangle is the image pointed to by the filepath in FORLOGO.
Page 74
Illustration 55: More Layout
Illustration 55 describes the HEADER_LOGO value as seen in blue.
Page 75
Questions and Answers
Question: Can we encase/enclose/cover in aluminum (or other metal) the scanner?

Answer: We STRONGLY urge the user NOT TO DO THIS.
Question: Generating a report is taking a very long time (eg. Longer that 30 minutes). Is this okay?
Answer: That depends on how long the scan is and how many faults and splices are found. It is
suggested to perform View Belt before Generate Report. Are there many faults and splices? The
software used to process scans (wringer) is VERY precise. It will find and catalogue EVERY fault and
splice. Even small faults are catalogued. The user may want to increase monochrome_threshold from
its default value of 1 to 2. Perhaps increase or turn on filter_y or increase filter_y_frequency. If this
problem persists, please contact your SteelSPECT dealer.
Question: Does the scanner head need to be close to the belt?

Answer: Yes! For best scan quality, mount the scanner as close to the conveyor belt as possible without
touching. Suggested distance with 2.5cm or less.
Question: Why do the first and last bias angles in a splice look weaker than the ones in the middle?
Answer: Half the number of conveyor belt cable ends exist in the first and last bias angles.
Question: Scan of the belt shows unexpected or strange faults (anomalies).

Answer: Strong residual magnetization or devices magnetizing the conveyor belt steel cords can be the
cause of said anomalies. Sources may include tramp metal detectors or welding cables left on/near
conveyor belt. Other sources of magnetization may exist. Please check with mine site staff as to what
other equipment maybe or may have been used near the belt.
Page 76
Question: Scan results show partial results, no results with a lot of noise or faults as seen in
Illustrations 56, 57 and 54.
Illustration 56: Broken connection between modules
Page 77
Illustration 57: Broken Illustration 58: Broken connection between

connection between modules
modules
Answer: Said problems seen in scan images, having eliminated the possibility of external or previous
magnetization, is a result of broken contact between modules. Please carefully inspect pin alignment
between modules. Are any pins broken, dirty, misaligned or missing? Were the hex screws holding the
Aluminium connecting rods tightned correctly? Are the target pads clear of obstruction? Please see
Illustrations 52, 53 and 54. If this problem persists, please contact your SteelSPECT dealer.
Page 78
Question: Broken pins?
Illustration 59: Broken Pins
Page 79
Page 80
Illustration 62: Targets
Page 81
Illustration 63: Working pins
Answer: Illustrations 55, 56 and 57 depict broken pins. These modules must have their pins fixed
before they are able to be used again. Please contact your SteelSPECT supplier for details.
Illustraion 58 depicts the targets which the pin make contact with.
Illustration 59 depeicts properly functioning pins.
Page 82
THE CARE AND FEEDING OF STEEL CORD CONVEYOR BELTS

OR
(FIVE BEST PRACTICES)
ABSTRACT
Steel cord reinforced conveyor belts are typically used in high tension bulk solids
handling applications such as steep incline or long overland conveyor systems.
They are also used in applications that require high impact resistance at the
loading zone.
Steel cord (SC) belting utilizes longitudinal runs of steel cords (cables) to provide a
conveyor carcass capable of withstanding much higher tensile loads and stresses
compared to fabric carcass belting, with an attendant substantial cost increase to
the SC belt itself, along with all other conveyor system components i.e. motor
drives, pulleys, gearboxes, idlers etc.
Accordingly, inspection and maintenance procedures and practices for all of these
conveyor system components have long ago been formalized and adopted. This is
not the case for the SC conveyor belt itself.
What is needed is a comprehensive overview of best practices to be followed to
ensure that an SC belt (especially a critical feeder or transport belt) provide its
maximum design life on a conveyor system and do so with minimum downtime
over that life.
BEST PRACTICES
1.) SC BELT INSTALLATION
The proper installation of an SC conveyor belt according to the SC belt
manufacturers guidelines and splice design layout is far more complicated and
involved than that of fabric belting. Aside from the best installation personnel,
the best vulcanizing materials and the best vulcanizing and belt handling
equipment, the SC belt manufacturers instructions must be strictly adhered to.
This is because the SC belt manufacturers splice designs and layouts have
been extensively modelled and tested so that the strength and operational life
of the splices are equivalent to the rest of the SC belt. If this is not done, the
splices very quickly become the weakest link in the conveyor system.
The above is apparently common and basic knowledge, but is not always
adhered to. Especially, since SC conveyor belt installation or replacement is
usually performed by a contractor. The mine site itself will usually have limited
installation supervision capability and lack the required knowledge needed for
ensuring that correct procedures are followed by the contractor. This, even in
cases where the mine site itself has vulcanizing equipment that it provides for
contractor use.
Accordingly, once the splices are “cooked”, i.e. vulcanized, the minesite will
have no idea as to the quality of their construction unless the remaining best
practices below are followed.
Page 83
2.) INSPECTION UPON SC BELT COMISSIONING

After the installation of a new SC conveyor belt, and before carrying any
conveyed bulk, the belt should be inspected via a steel cord scan in order to
determine:
i.) That the correct splice layout and design supplied by the SC
conveyor manufacturer was followed and employed;
ii.) That the “green” splices are all appearing intact;
iii.) That the belt is not exhibiting any premature tension breaks due to
gross mistracking or transition zone problems.
Steel cord scanning systems are available in both mobile or permanent forms.
Many service providers also offer steel cord scanning services with varying
degrees of fidelity and condition assessment.
3.) INSPECTION AFTER SC BELT REPAIR

After major repairs to the SC conveyor belt (i.e. patches) or the installation of a
new section (or sections), and before carrying any conveyed bulk, the belt
should be inspected via a steel cord scan in order to determine:
i.) That the new splices exhibit the correct layout and design supplied
by the SC conveyor belt manufacturer;
ii.) That the new “green” splices are all appearing intact;
iii.) That the new patches in the belt appear intact.
4.) REGULAR SC BELT INSPECTION

As part of routine SC conveyor belt maintenance procedures, and depending on
the service severity of the bulk handling system, the SC belt should be
inspected via a steel cord scan every six to twelve months in order to detect:
i.) Splice elongation and splice distortion/deformation that points
towards potential splice failure;
ii.) Cord damage within a splice that could lead to potential splice
failure;
iii.) Cord damage in close proximity to a splice that could lead to
potential splice failure;
iv.) Cord damage at the edges of the belt (tension breaks) which is
indicative of tension/mistracking problems;
v.) Cord damage along the centerline of the belt which is indicative of
transition zone tension/mistracking problems;
vi.) Condition of patches, new steel cord breaks, corrosion etc.
Page 84
5.) OPTIONAL SC BELT INSPECTIONS

A further part of SC conveyor belt maintenance should encompass conveyor
belt cover wear inspection procedures, the frequency of which is determined
by the service severity of the bulk handling system. Currently, this is mainly
performed manually (providing true top and bottom cover thickness to the
steel cord carcass via ultrasound inspection), although several automatic belt
thickness monitors are also now available (these only provide overall conveyor
belt thickness, not relative cover wear.)
Steel Cord Scanner (SCS) Technical Information

The steel cord scanning system (SCS) is available in modular (mobile) or
permanently installed forms. Standard SCS lengths are 1220mm, 1830mm and
2440mm. Custom SCS lengths are also available on request i.e. 1525mm,
2135mm, 2745mm and 3050mm.
The SCS provides a transverse resolution of 6.35mm across the width of the
belt and utilizes a system sampling (image slice) rate of 1070 per second. This
rate provides a matching longitudinal resolution of 6.35mm along the length of
the belt at a belt speed of 7m per second.
The SCS can scan belts running at speeds as high as 10m per second, and as
low as 0.1m per second, this latter capability is useful for performing splice
audits while the belt is wound/unwound across a splicing table.
The SCS can scan belts having ST ratings ranging from just under ST630 to
greater than ST10,000. This range in ST ratings is determined by the steel cord
diameters and the standoff distance between the SCS and the bottom cover of
the belt. This distance is recommended to be 10mm for ST1800 and lower and
can be as great as 30mm for ST6700 and higher. At the recommended standoff
distance the cable diameters that the SCS can scan is from 2.7mm up to
15mm.
Page 85

Escaner Electromagnético de Faja Transportadora-Steel SPECT

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Escaner Electromagnético de Faja Transportadora-Steel SPECT

Uploaded by

Copyright:

Available Formats

SteelSPECT User Manual

Thank you for purchasing SteelSPECT.

Rampart Detection Systems Ltd.

This manual is Copyright Rampart Detection Systems Ltd 2019

Very Strong Magnetic Fields!

Suggested scanning protocol..................................................................................................................7

How to assemble SteelSPECT.................................................................................................................9

First tests of assembled SteelSPECT....................................................................................................13

File and directory layout.......................................................................................................................39

Interpreting cable damage....................................................................................................................42

Report page layout.................................................................................................................................74

Questions and answers..........................................................................................................................76

The care and feeding of steel cord conveyor belts...............................................................................83

Scanner head power consumption:

Operating temperature range about -40 to +80 Celcius.

Suggested Scanning Protocol

1 x SteelSPECT scanner(modular or singular)

#1. Assemble SteelSPECT scanner if required.

Illustration 1: Unpacking modular SteelSPECT

How to assemble SteelSPECT

Illustration 2: Unpacking SteelSPECT and Head Module

Illustration 3: SteelSPECT module assembly

Illustration 4: SteelSPECT latch

Illustration 5: SteelSPECT latch closed

First test of assembled SteelSPECT

Illustration 6: Power and communications cable connection to SteelSPECT

Illustration 7: Power/communications connection to SteelSPECT

Finding a suitable scanning location

Characteristics of the optimal mounting position include:

List of personnel required:

* Required when belt is not steady.

Illustration 8: Ideal Placement of SteelSPECT scanner

Illustration 9: SteelSPECT mounted under conveyor belt.

Illustration 10: Power and communications cable connection to SteelSPECT

Illustration 12: SteelSPECT Mobile Scanning Interface Launch Icon

Illustration 13: SteelSPECT New Icon

Illustration 14: New Client Dialogue Box

Illustration 15: Client Name and Path to Client Logo

Illustration 16: Client displayed in Interface

Illustration 17: Conveyor Details

Please see Wringer Settings for details.

Illustration 18: SteelSPECT interface with Client and Conveyor

Illustration 19: SteelSPECT ready to Scan

Illustration 20: Pre Scan Settings

Pressing the Ok button will begin the scan.

Illustration 21: Connection Established and Connecting to SteelSPECT

Illustration 22: Scan is complete.

See Illustration 22.

Illustration 23: Processing a scan

See Illustration 23.

Illustration 24: View Belt viewer

Illustration 25: Report Generation Settings

Illustration 26: Report Edit

Illustration 27: Report Cover Page

Illustration 28: Report Table of Contents

Illustration 29: Report Summary

Illustration 29 shows a summary generated by the software for the report.

Illustration 30: Report Mini Map

The Scan Summary as seen in Illustration 30 shows three faults.

Illustration 31: Report Fault

Illustration 32: Report Fault

Illustration 33: Report Fault

File and Directory Layout