AUTOMATIC REAL-TIME DAMAGE DETECTION SYSTEM FOR CONVEYOR BELT

FIELD OF INVENTION

The invention relates to systems for real time monitoring industrial conveyor belt systems, and more particularly to a system for obtaining and analyzing signals from a plurality of sensors to provide for comprehensive conveyor belt health management.

BACKGROUND ART

Variety of industrial, mining and other applications exist for rotating machinery. Such machinery includes drive systems and material handling systems, such as conveyors and the like. Many such rotating machinery systems are periodically subjected to considerable loading that may result in latent defects or, in severe cases, catastrophic failure. In many cases, eventual failure is the result of continued cycling of machine elements in which defects have already occurred. Such defects may include cracks, tears, or other deformations in the mechanical structures that will eventually fail, even under normal working stresses. Because the failure of such machinery may lead to expensive repairs and down time, it is important to locate latent defects as early as possible to permit scheduling of necessary repairs before failures occur.

Conveyor belts are designed and used in heavy materials transport applications such as coal mining, ore mining, cement manufacturing operations, and the like. In many such applications, conveyor belts are located in underground mines where access to long stretches of belt and conveyor components is severely limited. In some cases direct visual observation of large portions of the belt run may be practically impossible. As can be appreciated, unexpected belt failures in these limited access areas can be dangerous and can cause substantial production delays.

As a result, methods and systems have been developed to monitor the condition of conveyor belts in operation in an attempt to predict when failures may occur. If such predictions are accurate, the conveyor system can be stopped and the belt repaired at an accessible location within the mine. While current systems offer some degree of manual monitoring, there is still a need for a fully automated belt monitoring system that is capable of collecting a variety of sensor data indicative of belt

condition, and of providing comprehensive information regarding the belt to a user. There is also a need for an automated system that can sense a major or imminent failure condition and can automatically stop the conveyor so that catastrophic system failure does not occur. Such a system should be modular and scalable to adapt to various belt types, sensors, and mine control equipment used throughout the material conveying industry. Further, the system should easily integrate with existing mine observation and control systems.

Failures due to latent defects are particularly problematic in conveyor and drive systems. Such systems, omnipresent in many industrial, mining, timber products, shipping and power generating facilities, to name just a few, are necessary for the transport of raw and processed materials. The systems typically include pulleys and rollers that directly contact the transported material, or that support conveyor belts or chains on which the transported material is deposited. In many applications, loads are quite substantial and the machinery must remain functional virtually at all times. Failure of elements of the machinery, particularly of pulleys and rollers, results in unscheduled repairs to bring the machinery back into service. Where the pulleys and rollers support a conveyor belt or chain, the belt may need to be removed to give access to the failed component, resulting in additional down time and expense.

Certain serious or obvious defects in rotating machine systems may be detectable by operations personnel based upon auditory or visual inspection. However, many defects escape such detection due to their latent nature or location. In conveyor systems in particular, certain rotating machinery may be located on booms, tunnels and the like, where physical inspection is very difficult. While some latent defects may be discoverable upon close inspection during machine servicing, for much critical machinery, such servicing is generally rare and must be minimized. Moreover, many latent defects are not readily discoverable even upon close visual inspection, without recourse to special equipment which is not typically available in industrial and other settings.

There is a need, therefore, for an improved technique for the early detection of defects in rotating machine systems. In particular, there is a need for a system for detecting such defects that can be applied on existing structures as well as new installations, and that can provide a reliable indication of a potential defect during operation of the machinery

SPECIFIC CASE

Steel Authority of India Limited (SAIL) is the largest steel producing company in India with a turnover of Rs 49,350 Cr. It has been awarded the “Maharatna” status by the Government of India. SAIL has five integrated steel plants with a combined capacity of 13.8 MTPA. The production and use of steel plays an important role in growth of every sector. The Government of India, in the draft NSP- 2012, has envisaged a crude steel capacity of 300 MTPA by 2025 in domestic market. SAIL has laid out an ambitious growth plan of 48 MTPA of crude steel in its VISION 2025.

Durgapur Steel Plant (DSP) is one of integrated steel plant of SAIL with hot metal capacity of 2.45 MTPA. It products are Wheel and Axle for Railway, TMT bar Earthquake resistant construction structural, CC Blooms. It is on the path of growth with projects like Medium Structural Mill and Bloom & Round Caster.

Raw Material Handling Plant plays a very important role in an Integrated Steel Plant. It is the starting point of an integrated steel plant, where all kinds of raw materials required for iron /steel making are handled in a systematic manner e.g., unloading, stacking, screening, crushing, bedding, blending, reclamations, etc. These activities are done by a series of conveyor belt. In other words conveyor belts are life line for a material handling plant.

In Raw material Handling Plant (RMHP) of Durgapur Steel Plant, a total of 165 conveyors are running with a length of approximately 44,000 meter. The health of these conveyors are monitored and maintained by time based inspection and maintenance schedule. But maintaining such a large network of conveyors is not an easy task.

Unplanned repair of Vulcanizing joint of Conveyor Belt takes approx 16 – 20 Hours, which impacts the bottom line of the company, as per importance of belt, and based on whether the belt is in Tippling, Production, Despatch, Screening or Crushing route. For example when belt is in tippling routes it leads approx detention of more than 100 wagons i.e. demurrages of two rakes for 16 Hours is about 16 Lakh. When the belt is in Production / Despatch routes it leads approx shortfall of Production / despatch to the tune of 11200 Tonnes of sinter/blend mix which reflects monetary losses is about 19 lakh.

In case of longitudinal or Side cut we have financial impact of unplanned repair of vulcanizing joint with additional cost of damage belt. Cost of belt is too high (Rate of one meter conveyor belt is Rs. 3250/-) due to which financial impact becomes very high. In our department Length of each Conveyor belt varies from 200 meter to 900 meter. So cost of damage belt, as per length of belt is from 6.5 lakh to 19 lakh.

OBJECT OF INVENTION

A great requirement was felt to develop an automated system which will monitor the faults in the conveyor like joint failure /through cuts/side cut/damaged capping, round the clock. Therefore herein disclosed is an automatic system with belt protection logic (In both mode PLC and Relay Logic) which monitors conveyor belt for all major faults round the clock with monitoring facility in central control room through Interface.

The disclosed system provides complete protection of all major faults of conveyor belt i.e. longitudinal cut, side cut of belt, failure of vulcanizing joint of belt, damage of capping of belt. It can also be used to stop material spillage during belt sway (misalignment) of belt. As these abnormalities occur in belt, the developed system detects it in early stage, stops the drive motor in real time and a signal with that particular fault appears in an interface in Central control room.

The basic principle of this system is that every major faults of conveyor belt joints/through cuts provides a linear push to the device which converts it into rotary motion and provides an electrical signal through a proximity sensor for further processing in electrical circuit. The system is designed in such a way that it always give positive logic in normal condition and in case of any fault in conveyor belt it gives restricted rotating motion to proximity sensor target, the sensor then gives a negative signal to belt fault protection circuitry. It detects all major faults which can occur in a conveyor belt.

SUMMARY OF INVENTION

The disadvantages heretofore associated with existing systems are overcome by the disclosed design for a conveyor belt monitoring system.

A conveyor belt condition monitoring system is therefore disclosed that includes two rotating pulley which rotates during fault condition of conveyor belt and convert linear

motion of belt element in rotating motion of pulley which change polarity of electrical signal through target of proximity sensor which is mounted along the structure of conveyor belt as sensing condition , a processing system for receiving signal from sensor , analyzing the signal to access condition of conveyor belt element and display for providing a visual representation to user of the condition of conveyor belt element.

The complete detector system may be arranged cross section of structure of conveyor belt and sensor adjacent to the structure of belt.

The display may be only a part of a user input and monitoring console operable connected to the processing system so that a user may interact with and control the monitoring system. The visual representation provided by the display may include one or more representative information configurations of the group consisting of: a learn mode configuration, a historical monitoring configuration, a non-historical monitoring configuration, a full-screen configuration, and a refined full-screen configuration.

In another aspect of the invention, the system may be operable connected to a data communications system(s), such as a facility-wide monitoring system for which conveyor belt monitoring is only a portion, an Intranet, a virtual private network, and/or the Internet so that the condition of the conveyor belt may be communicated, analyzed and assessed locally and/or remotely.

In yet another aspect, the system may include a programmable logic controller (PLC) connected via an Ethernet link for receiving data about the belt element. The controller has modules so that portions of the processing system may be selectively integrated into a facility-wide industrial monitoring system.

One object of the invention is to provide an improved conveyor belt condition monitoring system, which is capable of collecting a variety of conveyor belt sensor data indicative of belt condition, irrespective of the OEM belt or belt elements analyzed by the sensors, and provide comprehensive information regarding the condition of the belt to local and remote users. Another object of the invention is to provide such a system that is scalable to adapt to various belt types, sensors, and mine control and observation equipment and systems used throughout the industry.

Related objects and advantages of the invention will be apparent from the following description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Fig. 1 illustrates the elements of vulcanizing joints in accordance with the present invention;

Fig. 2 illustrates the open ply defect of belt which is become vertical in different position of endless belt in accordance with the present invention;

Fig. 3 illustrates the side cut defect of belt which is become vertical in different position of endless belt in accordance with the present invention;

Fig. 4 illustrates the picture representation of major fault of belt and its premature condition in accordance with the present invention;

Fig. 5 illustrates the picture representation of carrying side sensor end view in accordance with the present invention;

Fig. 6 illustrates the picture representation of carrying side counter weight end view in accordance with the present invention;

Fig. 7 illustrates the circuit diagram of carrying side in normal running condition in accordance with the present invention;

Fig. 8 illustrates the circuit diagram of carrying side in actuated condition in accordance with the present invention;

Fig. 9 illustrates the picture representation of non-carrying side sensor end view in accordance with the present invention;

Fig. 10 illustrates the picture representation of non-carrying side counter weight end view in accordance with the present invention;

Fig. 11 illustrates the circuit diagram of non-carrying side in normal running condition of detector in accordance with the present invention;

Fig. 12 illustrates the circuit diagram of non-carrying side in actuated condition of detector in accordance with the present invention;

Fig. 13 illustrates the relay panel logic and interface with PLC in accordance with the present invention;

Fig. 14 illustrates the PLC program for fault and monitoring in accordance with the present invention;

Fig. 15 illustrates the interface showing faulty conveyor (in red) with particular fault in accordance with the present invention;

Fig. 16 illustrates the interface showing alarm history page shown as red in accordance with the present invention;

DETAILED DESCRIPTION

Basic features

Basic principle of this system is that every major faults of conveyor belt joints/through cuts provides a linear push to the device which converts it into rotary motion and provides an electrical signal through a proximity sensor for further processing in electrical circuit.

The disclosed system is designed in such a fashion that it always give positive logic in normal condition and in case of any fault in conveyor belt it gives restricted rotating motion to proximity sensor target, the sensor then gives a negative signal to belt fault protection circuitry. The system includes two devices for complete protection of a conveyor belt. One device is installed for carrying side and another device has been installed for non-carrying side of conveyor belt. Both devices have same arrangements and parts except non carrying side having addition Horn Rod and Feed plate which are essential for detecting through cuts/side cut and joint condition monitoring.

Optional Features

During belt sway i.e. when belt goes out of normal condition, material spillage starts, Device immediately stop the belt and reduce cleaning activities.

1. Wastage of conveyor belt without utilising its proper life affects also

Environments.

2. Impact due to damaged belt capping.

Other than loss of production and demurrage charges it involves extensive manual recycling of material. In addition to this if belt is run without proper cleaning it further leads to the damage of the belt, making it a vicious circle.

Illustration of best workable embodiment of the invention:

1: First step:

Identification of early stages of major faults of Belt:

In case of early detection of any abnormalities of belt, proper action can be taken and we get sufficient time to plan so that it cannot convert in major faults.

A. Failure of vulcanizing joint:

When any conveyor belt is used for conveying materials, it is made endless. For making endless of belt vulcanizing joint is done. Due to running in different condition like temperature variation, rubbing with idler, scrapper and chute of belt, it starts either damaging or opening the ply of joint slowly.

When vulcanizing joint is done, belt ply as shown in Fig. 1 (3) to (5)) is taken in different length for proper bonding and as per direction of belt motion its jointing is done so that damage of joint is minimum. So any belt having two ends one is carrying side (belt surface which carry materials) and another end is non-carrying side. As per conveying motion of belt joint direction upper part is kept opposite to motion direction.

When joint starts damaging, first of rubber opens and then ply of different stages start opening, after that joint fails and belt snaps which is major breakdown of belt. So opening of ply or rubber is the initial stage of any joint failure of belt.

As shown in Fig. 2, the open ply of belt becomes vertical in different position of endless belt. Vulcanizing joint of belt having two ends one towards carrying side and another towards non carrying side. The carrying side open ply becomes vertical in return side of belt and non-carrying side open ply becomes vertical just below carrying side which is essential to know to detect it through detectors and deciding position of detectors.

B. Side cut of belt:

Due to edges of chutes .sharp edges of rollers or misalignment of scraper or abnormalities of belt, belt starts to damage from side and as per rotating motion of belt it gradually increases. Hence the width of belt becomes narrow which lowers down the carrying capacity of belt and also sometimes it gets wrapped with pulley and protective system i.e. pulls chord switches, belt sway, ZSS targets creating major breakdown. The hanging belt in initial stage of belt damaging process from side cut as shown in Fig. 3.

C. Longitudinal cut :

Belt conveying of different ferrous material like Lump iron ore, iron ore fines and Lime, dolo which comes from mines having scraps which get stuck-up with chute and starts damaging. Also sometimes chute liners, structure of chute get stuck with belt and through cut starts. In this condition material starts falling from belt and whole belt gets damaged due to through cut. This is very costly breakdown because belt cost included with process loss (Production loss, Demurrage loss)

In this condition, we are taking falling material as initial stage of major breakdown longitudinal cut and detector detects falling materials and stops the belt with minimum damage.

D. Damage capping:

Capping of belt is done when vulcanizing joint due to rubbing develops holes in belt. Due to damaged capping material starts falling from belt. In this condition, we are taking falling material as initial stage of damage capping fault to detect through detector.

E. Belt sway of belt:

When the belt running position becomes misaligned then the belt comes out from normal position and material starts falling on deck plate. In this condition, we are taking falling material as initial stage of belt sway fault to detect through detector.

In this way, the initial stage of major faults can be summarized as shown in Fig. 4, in which detector detects in early stage to prevent the major faults of belt.

Summaries in Tabular form:

Major faults Initial stage which detector detects in early

stage
A. Failure of vulcanizing

joint Open ply of joint
B. Side cut of belt Hanging belt piece
C. Longitudinal cut Falling materials from belt
D. Damage capping Falling materials from belt
E. Belt sway Falling materials from belt

2: Second step

Working of detector in early stage of major faults:

For complete protection of belt from all major faults, we design two detectors one for carrying side and another in non-carrying side.

Carrying side detector:

As shown in Fig. 5 and Fig. 6, two adjustable brackets (7) are fixed with belt structure (3) and a return idler (6) with extended shaft (8) is placed below belt. Idler (6) position i.e. distance between belt and return idler is adjusted as per user requirement which determines the length of ply open taken as detection condition for detector. In this way, it can be adjusted on which length of ply detector will work. Then one side of Pulley (6), a target (5) which metallic strip welded with pulley and on another side which just opposite to target(5) , a counter weight (9) welded with pulley. Function of counter weight (9) is to take pulley position such that target is always stable in one position during normal condition. Counter weight is also used for detector keep normal condition when any vibration comes during running condition of belt and how much impact allow rotation to pulley during fault condition. Counter weight is also used to avoid small rubber pieces of belt for detection through detector. With structure a mounting holder (2) is fixed and in this holder threaded Proximity sensor (1) fixed. Sensor is threaded, so its sensing distance can be adjusted with target (5) which is fixed on pulley. Sensor (5) is always in sensing condition with target (5) and always gives positive logic in relay panel during normal

condition. As shown in Fig. 6, counter weight and target in position (A) in Fig. 6 in normal condition in which sensor sensing target and giving 110V output for relay. So relay in pickup condition during normal condition means detector gives positive logic during normal condition.

As shown in Fig. 8, when ply of belt open in carrying side it get vertical in return side of belt as shown in Fig. 2 which gives impact on idler (6) and idler rotates towards belt running direction. As idler rotates, welded target (5) and counter weight (9) rotates go to position (B) as shown in Fig. 7. As shown in Fig. 7, as target (5) position in (B), Sensor (1) polarity changed and gives 0 volt in output and so associate relay KS1 drop as shown in Fig. 12. As circuit diagram in Fig. 12, as KS1 drop, KSET relay get holds and belt stops in real time. In Fig. 12, two interlock given i.e. contact of K1 and K9; it is used for Kset relay for holding. So fault will set when belt is running and its command relay K1 and Slip/ Snap relay K9 of belt pickup. In other words fault will only set when belt is running and other condition of Relay K9 is used to avoid initial start for long length belt specially Yard conveyor belt. Contact of Relay K43 (which stop relay of belt) is used in holding condition which reset fault after manual intervention i.e. stop to be given and then release it. It is auto resetting system so that after fault actuation detector comes back to again in normal condition, it is used to verify detector system in healthy condition itself and any fault in detector like sensor damage, cable snap, supply missing, misalignment in detector ,it verify as unhealthy condition of detector.

Relay Ks1 input and Relay Kset input taken as PLC input, which is normally high in PLC as shown in Fig. 13. In PLC S7, a program is written which set the fault as Sensor polarity changed during fault condition and make belt to stop. In HMI as in Fig. 15 that particular belt shows as stop and further exploring the fault in which fault belt stop it shows that belt stop in PLY open carrying side fault as shown in Fig. 15. In Fig. 16 that fault register in Alarm page in real time which is used for belt fault history analysis.

Non Carrying side detector:

Fig. 9 to Fig. 12 for non-carrying side detector it’s all operation same as carrying side detector. It is placed below material carrying side of belt. As shown in Fig. 9 material carrying side belt (4) is running on toughing idler set (12), so running conveyor take shape as toughing idler and it becomes almost U shape. So when placed carrying

side detector only 50% of vulcanizing joint of belt covered through detector. Both side of 25% of belt covered by detector with fixing of two Horn rod s (10) on idler (6) with same inclination as toughing idler. Horn rod inclination kept same as toughing idler inclination (12) and below 30- 40 mm of belt, so that during belt sway it not touch with belt. Now any ply open of belt in carrying side or side cut of belt, it gives rotation the detector either through idler (6) or Horn rod, so that detector position changed on (B) of Fig. 12 and Sensor polarity changed 110 V to 0 V & drop the relay KS2 (Fig. 13) in relay panel and same logic as carrying side belt stop in real time and fault and alarm History activated with fault.

For longitudinal cut, Belt sway and damage of capping and any fault which initial fault is material falling from belt, we fixed a feed plate (11) with idler in Fig. 9 in direction of belt. When material starts to fall from belt due to this fault, feed plate (11) rotates the detector and Sensor polarity changed to 0V as shown in Fig. 12.Then belt stop as shown protection and monitoring logic in Fig. 13 and Fig. 14.

Installed parts and part wise function:

Sl

No.
Parts
Installed Area
Function

1 Adjustable

Brackets At bracket of conv. channel 1. Adjust distance between Belt and

Device (Normally 60-80 mm)
2. Return idler and other parts mounted on

this

2

Idler In grooves of

Adjustable

Brackets
1. Rotates sensing target during fault condition for generating fault signal.
2.Sensing Target and counter weight are

mounted at 180 degree
3.Shaft extended up to adjustable bracket

3
Counter weight

Idler 1. Keeps device in normal condition to

avoid false tripping due to vibration when conveyor running
2. Auto Reset to normal position after any

fault in belt rotates Idler

3. Locks the motion of idler as per

requirement and proximity sensor position.
4. Adjustment of extent of a fault(length of ply/joint opening etc.) as per requirement.

4 Sensing

Target
Idler
1. Sensing target for Proximity sensor
2. Locks the motion of idler as per requirement and proximity sensor position

5
proximity sensor At channel in

separate mounting
1.Electrical positive signal during Normal condition
2..Electrical negative signal during fault condition

6

Horn Rod At Idler at same

angle of toughing of belt
1. Used for to cover up joint area in non carrying side which not under Idler
2. Used for side cut of belt

7
feed plate
at Idler 1. During longitudinal cut material falls on

it rotate Idler
1. During belt sway material falls on it

rotate Idler

Installation Area Of device in Conveyor belt

1.Non carrying side device always installed near to receiving chute of conveyor belt as maximum cases belt start to damage from receiving chute so that device can detect the damage with minimum damage of belt.

2. Carrying side device fixed below the return side of belt facing towards the surface of carrying side of belt.

Actual impact measured in three vital conveyor belts in three months of RMHP:

Belt No. 37C1 42C2 36C2

Belt Length

307 Mtr.

920 Mtr. 268

Mtr.
1. Joint

Failure

No. of Breakdown

2

9

2
Matured 1 6 2
Premature 1 3 0
Shutdown hours

saved

Matured

6 Hr.

36 Hr.

12 Hr.
Premature 12 Hr. 36 Hr. 0
Cost 11106 44424 7404
2.Longitudinal cut/ side cut No. of

Breakdown

1

2

0
Break down 14:30 Hrs 29 Hr. 0
Belt saved 296 M. 1800 M. 0
Cost Saved @

Rs.3250/m

962000

5850000

0
3. Material

Handling No. of Belt

Change

3

11

2
20 Man/Hr. 60 220 40
Rs.80/Man hr. Cost 4800 17600 3200
4. Less Device

cost

8950

8950

8950

15

5. Total cost

Saved

Total Saving is 68.7 LAKH

Highlight the inventive steps:

Our innovation can be used in any industry which uses conveyor belts for conveying

materials.

Existing Reality New Reality created by our Innovation
1 Time based inspection schedule of conveyor belts (only for Vulcanizing Joint) Automatic conveyor belt damage detection.
(Vulcanizing joint and Through Cut/side cut0
2 During Damage no fault protection to stop belt till it stops on major failure. Round the clock belt fault protection system and monitoring through HMI in Central Control Room
3 Frequent belt damage Belt damage in controlled

SALIENT FEATURES OF THE INNOVATION:

• Easy to develop or design

• Easy to install

• Simple to understand the working procedure of system

• Round the clock protection of belt from major faults

• Spares used for the device are normal spares of Material Handling Plant

• Provides fault protection in both Local and Auto running system

• Simple PLC (Programmable Logic Control ) Programming as shown in Fig.

14.

• Simple Relay logic

• Fully Automatic monitoring facility in central control room through Interface – Fig. 15.

• Fault History in PLC (Programmable Logic Control ) as shown in Fig. 16.

Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

WE CLAIM:

1. An automatic real-time damage detection system for conveyor belt, comprising:

at least two detectors fixed on the structure of conveyor belt;

at least two proximity sensors, outputting contact and non-contact condition signals from a corresponding metallic target;
a relay logic and PLC for transmission of signals and protection from fault and monitoring through an interface from remote place; wherein the detectors are mounted with Feed plate, Horn rod, counter weight, sensing metallic target and extended shaft idler with adjustable bracket.

2. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein the detectors are placed on carrying and non-carrying sides of the conveyor belt.

3. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein the adjustable brackets (7) are fixed with belt structure (3) and return idler (6) with extended shaft (8) is placed below belt.

4. An automatic real-time damage detection system for conveyor belt as claimed in claim 2, wherein distance between belt and return idler is adjusted as per user requirement which determines the length of ply open taken as detection condition for detector.

5. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein on one side of idler (6), a target (5) which metallic strip is welded with pulley and on another side which just opposite to target (5), a counter weight (9) welded with pulley.

6. An automatic real-time damage detection system for conveyor belt as claimed in claim 4, wherein the counter weight (9) is configured to take pulley position such that target is always stable in one position during normal condition, counter weight is also used for detector keep normal condition when any vibration comes during running condition of belt and how much impact allow rotation to pulley during fault condition.

7. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein the counter weight is adapted for keeping the detector in normal condition and under condition of any vibration during running condition of belt, allows the rotation to pulley in a fault condition.

8. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein the sensor is threaded, so that the sensing distance can be adjusted with target (5) which is fixed on pulley.

9. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein sensor (5) is configured for sensing the condition with target (5) and gives positive logic in relay panel during normal condition.

10. An automatic real-time damage detection system for conveyor belt as claimed in claim 1, wherein in normal condition, the sensor sensing target gives 110V output for relay so that the relay is kept in pickup condition and detector gives positive logic.