A Review of Fault Detecting Devices for Belt Conveyor Idlers

Abstract

The shift towards automated inspection methods represents considerable progress in conveyor system maintenance, enhancing safety and efficiency while posing challenges in data analysis and implementation costs. This study critically analyses sensor technologies and inspection methods for detecting faults in conveyor belt idlers, highlighting their essential role in preserving the operational integrity of industrial conveyor systems. By synthesizing various research findings, the study assesses the effectiveness of different sensor devices in identifying defects, including built-in sensors, fixed sensor options like acoustic, ultrasonic sensors, cameras, accelerometers, and Distributed Optical Fibre Sensors (DOFS), as well as mobile sensor systems. Our findings emphasize the accuracy of robot-based systems in identifying bearing defects, the comprehensive coverage provided by drones for medium-scale inspections, the constant monitoring offered by integrated idler sensors, and the ability of fixed sensors to detect mechanical faults despite environmental challenges. This research adds to the ongoing discussion on enhancing conveyor system dependability through technological advancements, providing insights into potential future developments that could further refine maintenance strategies in the sector.