Development of Advanced Conveyor Belt Monitoring System

(Bluefield)—A research initiative at the new Tazewell County Business and Technology Park near Bluefield, VA could have a powerful and positive impact throughout the mining industry.  Fenner Dunlop Conveyor Belting, the world’s largest manufacturer of conveyer belting for mining and industrial applications, is building a research center adjacent to the 680 acre Bluestone Technology Park in Tazewell County.  The facility features a 65-foot test conveyor system.  At the same time, the Center for Applied Research and Technology (CART) at Bluefield State College is helping create an “intelligent” steel cord belt monitoring system and providing technical support in Fenner Dunlop’s belt monitoring system research.

“The monitoring system applies sensor technologies that detect potential belt rips and tears and monitor its overall bent condition,” explained Bruce Mutter, CART President and the College’s Associate Dean for Applied Research, “and can help to prevent significant operating losses.”  Mining operations rely on conveyor belts to move mined material from the working face to a processing plant.  Longwall mining operations can generate revenue at a rate of $1,000/minute and a halt in operations often lasts for four hours or more, resulting in a $240,000 loss in revenue.

“By developing an automated monitoring system, we can help optimize the efficiency of the process and can provide information that identifies when preventive maintenance needs to take place,” Mutter continued.  The Fenner Dunlop facility’s test belt conveyor system is designed to replicate the system used at a longwall mine.  “Our experiences with autonomous vehicle robotics has been very helpful as we apply the lessons learned to an industrial process, looking at current state-of-the-art measurement methods and considering refinements that measure belt wear and tear,” he added.  “In phase two, we will research even further improvements to the process, by utilizing emerging technologies.

“Our goal is to develop an advanced belt monitoring system, utilizing several known techniques and technologies, to gain as much information on belt condition as possible,” explained Mick Twigger, Senior Electrical Engineering Manager at Fenner Dunlop’s Tazewell County facility.  “CART is researching areas that can help Fenner Dunlop in developing an advanced system to gain market leadership.”

Mark Myers, a Bluefield State College graduate and a former team leader of the College’s Intelligent Ground Vehicle Competition and CART’s  DARPA Grand Challenge teams a few years ago, is now a lead engineer with Fenner Dunlop, and Jim Spencer, also a BSC alumnus, is Tazewell County Public Service Administrator.  “We are proud that Fenner Dunlop decided to come to Tazewell County to conduct this research,” he stated.  “The concept behind the Bluestone Business & Technology project is to create technology-related jobs.  What better way to do this than research partnering CART and Fenner Dunlop?

“Our region is uniquely positioned to help our country regain most of its energy independence and working with Fenner Dunlop creates an outstanding opportunity for CART to apply ingenuity to the industry most vital to its economy,” Mutter added.