Smart Conveyor Belts for Structural Health Monitoring and Weigh-In-Motion

Imagine Intelligent Materials (“Imagine”) has developed and tested graphene-based sensing surfaces on conveyor belts to allow real-time monitoring of the structural health of the belt, the strain it is under, damage to the belt and the weight on the belt.  Imagine These sensors are incorporated into existing materials without changing their mechanical properties and use edge-based monitoring to allow sensing where sensing has not previously been practical or economic.

This project demonstrates a proof-of-concept smart belt and determines the technical steps to a commercial product.

The challenge in adapting the stationary sensing technology to moving belts used in mining are primarily around attaining sufficient signal sensitivity and resolution and engineering the sensing electronics and materials to be robust enough to operate reliably in a continuously moving and harsh environment. The concept clearly works, with both stationary and in-motion testing showing reliable responses to damage, weight and strain sensing. Imagine has demonstrated development of the smart belt concept from TRL2 to TRL4.

Key outcomes from the project are:

• Sensing graphene coatings using existing materials produced by Imagine (imgne® X3) have been prepared on the surfaces of existing belt rubber covers;
• A series of stationary tests demonstrate structural health monitoring (rips, holes, damage) and weighing;
• In-motion testing detects movement and strain;
• Optimisation of the graphene coating is required to improve adhesion and to incorporate the graphene sensing surface into existing belt materials;
• Several informal workshops have been held with mining industry subject matter experts about the capability need for the sensing belt;
• A literature review of the possible health implications of the use of graphene has been prepared with no special risk identified.