Development of an automatic system for steel-cord core belt diagnostics.

 The system comprises a number of modules integrated in the system’s core. The core manages both the source and processed data base and allows for data exchange between the modules and the base. The modules are built independently, which ensures natural order of system construction. Prior works using the measurement head of EyeQ system showed that some modifications allow to increase the resolution of source data. The source signals were sent to LabView environment and processed with interactive tools available in the program.

 In order to enable the user to perform measurements with the customized system, it was necessary to develop a dedicated application for data acquisition that works on a portable device (tablet) – the acquisition module. Although the acquisition module is an independent application that allows for the handling and visualization of source data and for performing operations that prove useful on location (at the conveyor), it is not sufficient, as the data must be imported to a database, where they could be retrieved from by other modules, such as visualization module, analytical module, or the module for report preparation.

 In the next step, it was thus necessary to create the system’s core, which would manage the data and allow for their archiving. The structure of the database managed in the core is not finite, as the addition of further modules will lead to the creation of other files comprising source data processed to the forms in which other modules might be able to use them. Hence, during the system’s development process, the core will be also developed to include new functions, as new modules are added to the main system. At this stage, the implemented system’s core that manages source data allows to retrieve data from the device operating on location and to store them in a specially designed folder structure. Source data management is the most important part of the database, as all other modules will need to access it.

 Validation of the system was carried out at the test rig located at the Institute of Mining Engineering, Wrocław University of Technology.  The tests were carried out with steel-cord belt 1600, 400 mm wide and 17 m long. The belt’s speed was between 0 and 7.5 m/s. The tests were carried out to prove that all modules operated effectively and correctly. Verification, as well as both hardware and software adjustments, were performed systematically. After approvals and necessary adjustments, the system was ready for measurements on conveyors located in the mine.

 The tests of the system were carried out at Turów brown coal mine on four overburden conveyors and two ramp conveyors. The tests were aimed to check its individual functions, such as:

- its proper start-up and proper operation of its individual components,

- proper registration of signals from all 24 channels,

- identification of the loop on the basis of the signals coming from the installed markers (magnets),

- acquisition module and quick preview of the recorded data,

- other measurement parameters, such as head assembly position and its distance from the inspected belt, the position of the magnet field in relation to the magnetic head.

Tests at the mine were also aimed at collecting information on the system’s operation in different environmental conditions, its resistance to accidental faults or the influence of factors beyond control (electromagnetic fields, excess voltage, power supply from a generator). The measurement box was also checked for functionality (the degree of protection of the system’s elements against coal dust and moisture).