LATAM-SHM-2026

Steel Wire Rope and Conveyor Belt Monitoring Systems at Critical Industrial Facilities

  • Slesarev, Dmitry (INTRON PLUS)

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Steel wire ropes are being used in different hazardous industrial facilities, such as mining, lifting, drilling. Steel-cord belt are widely applied in mining and primary processing industries. Failure of this structural unit can cause a severe economical losses or even accidents. It is important to implement condition monitoring of such units. The most dangerous rope defects: corrosion, abrasion and wire breaks - can be detected by means of magnetic rope testing (MRT). Main steel-cord belt defects – cord breakage and splice elongation can be detected by electromagnetic testing. Application of common techniques is restricted by the necessity of qualified staff for inspection operations and result’s interpretation. Automated monitoring systems give a modern solution of this problem. The automatic rope monitoring system Intros-Auto consists of magnetic head (MH) placed at the rope and control and display unit located at operator console. It can perform both as a standalone instrument and as a part of enterprise information system. If necessary detailed results analysis is possible after downloading of inspection results. To enable an automatic data interpretation monitoring system should ensure high confidence and repeatability of measurement results and low susceptibility to external disturbances of different art. The monitoring system should also confirm with ISO4309, meet the requirements of ingress protection IP65 or higher and be explosion proof, if necessary. These requirements are fulfilled by the Intros-Auto rope monitoring system (from INTRON PLUS), which was successfully implemented and run at more than 30 mine hoists and several dozens of drilling rigs for everyday rope condition monitoring. An automatic steel-cord belt monitoring should be maximally robust to environment influence, not need any regular service and enable remote operation, as it stays typically outdoors and in very dusty ambience. It should automatically detect and locate breakage of individual cords and employ recognition with quantitative estimation of every belt splice. The Introcon-Auto belt monitoring system includes a scanner (mounted under the belt) and control computer, connected with a scanner by a standard Ethernet interface. Computer makes a full automatic data processing, gives an operator customized information about belt technical condition and send monitoring results into enterprise information system.