Health Monitoring of Conveyor Belt Using UHF RFID and Multi-Class Neural Networks

Abstract

Conveyor belts in mining sites are prone to cracks, which leads to dramatic degradation of overall system performance and the breakdown of operation. Crack detection using radio frequency identification (RFID) sensing technology is recently proposed to provide robust and low-cost health monitoring systems for conveyor belts. The intelligent machine learning (ML) technique is one of the most promising solutions for crack detection and successful implementation within the IoT paradigm. This paper presents a conveyor belt structural health monitoring (SHM) model using ML and Internet of Things (IoT) connectivity. The model is extensively tested, and the classification is conducted based on simulated data obtained from an Ultra High Frequency (UHF) RFID sensor. Here, the sensor is laid on a belt, and the data are obtained at different crack orientations of vertical, horizontal, and diagonal cracks, for varying crack widths of 0.5 to 5 mm at 10 different locations on the sensor. The ML model is tested with different input features and training algorithms, and their performances are compared and analysed to identify the superior input feature and training algorithm. This method produces high accuracy in determining crack width, orientation, and location. The findings show that the proposed detection system based on ML modelling could detect cracks with 100% accuracy. The proposed system can also distinguish between vertical, horizontal, and diagonal cracks with an accuracy of 83.9%, and has a significant identification rate of 84.4% accuracy for detecting crack-width as narrow as 0.5 mm. Moreover, the model can predict the region of the crack with an accuracy of 95.5%. Overall, the results show that the proposed model is very robust and can perform SHM of conveyor belts with high accuracy for a range of parameters and classification scenarios. The method has huge industrial significance in coal mines.