Operational Enhancement of the Ferromagnetic Object Detection System for Belt Conveyors

Belt conveyors are essential systems for the continuous transport of various materials in many sectors and applications, including heavy industry or mining, which are characterized by demanding environmental and operational conditions. Our research is focused on the development of the system based on magnetic sensors for the detection of ferromagnetic objects. These detection systems are designed to prevent damage to conveyor belts and the downstream vehicles, machines, and processing equipment involved in material transport and processing. By detecting hazardous foreign objects, they help avoid belt damage or tearing, thereby reducing operational disruptions and the associated maintenance and repair costs. Our study confirmed that in addition to the development of the hardware and software solutions, it is also necessary to develop methods for the processing and evaluation of the data recorded by the detection system, as the data represent a valuable source of information not only for the operational workers but also for the managers and are very helpful in the creation of the sustainable transportation system. The article describes an innovative application of the Weibull distribution for the operational enhancement of the system and its comparison to the conventionally used histograms. In addition to that, the utilization possibilities of the obtained statistical data to evaluate the belt conveyor loading for a better planning of the process, to monitor the work of the operational or other employees’ quality of the supported material, or to reveal failures of the detection system or even of the belt conveyor are overviewed and discussed.