​

​ 

1.     Introduction

In many
industries, power transmission rotors and transport conveyors are an important
part of material handling systems,

especially in the mining and cement
industries. That is why idler failures in conveyor systems can lead to belt
damage, cause fire, 

costly downtime and loss of production. 

To solve this
problem, POLTEC's rotating body and idler sound monitor device was developed to
detect defects in the rotating part

bearing and idler early. The POLTEC sound
monitor kit distinguishes between the sound of the idler that is operating
normally and 

the failure sound, and the maintenance worker can quickly and
safely detect the defective idler around the machine and conveyor belt 

without
having to do direct inspection at the site. 

Therefore, this equipment is used
to detect failures of rotating bodies such as motors and idlers, which are
configured on conveyors in 

industrial sites that transport coal or cement, and
can remotely detect failures of rotating bodies by configuring an automated
system.

Also, it can inform the user through the monitor screen. Unlike the
conventional method in which a person intervenes and directly 

approaches the
site to determine the failure of a motor or idler, a number of detection modules
are placed around the conveyor to be 

measured to check the failure in the
office.I

​

 In displaying result
information, it is divided into normal, caution, warning, and dangerous stages
according to the degree of failure, 

and the degree of failure according to the
frequency of occurrence can be displayed on the user's HMI monitor screen to
notify the administrator. 

These detector modules use a non-contact method using
sound, and are deployed around the rotating body or idler without contacting to
the 

motor or idler, so that the installation and maintenance is easy, and the remote
user can control the operation of the modules placed in the field. 

For example,
startup and shutdown can be selected, specific modules can be selectively
operated from multiple installed modules, and the site 

manager can remotely
restart the device or adjust the environment variables of the device using the
touch panel.

​

​The POLTEC system consists of a
detector module, communication gateway, PLC, and HMI device. 

the detector
module classifies the sound data with an artificial intelligence based on Deep
Learning algorithm, 

is configured to be connected to the PLC through an
industrial standard communication system, and effectively 

provide site
identification information to the remote users.

​

The information
in the HMI is as follows. First it shows the working status as a bar level
graph, allowing the user to 

easily understand the failure trend.

​

​

Second, it provides
a data accumulation graph. In the graph, the degree of failure is recorded at
regular intervals and 

displayed on the screen, so that the administrator can
monitor the trend of failures in one day or at a fixed time. 

And it is designed
to be able to store and store this information on the additional SD card.

​

​

Thirdly, the screen shows schematic diagram of the connection for the
modules installed on the site and the specific conveyor

line to enhance the
user's understanding, and marks the problem section of the motor or idler so
that the location of replacement 

and repair can be quickly identified.

​

​

Failure detection module of the
rotating body is a device that directly measures the failure by placing a
number of devices in the field. 

The measured result is transmitted to the
office by linking the information like DeviceNet, an industrial communication
protocol, 

and the module has a high sensitivity microphone and performs function
that analyzes sound information generated in the field 

up to 20 kHz, allowing
precise analysis of the sound in the field. 

​

2.     Failure detection method

Conveyor motor and idler
failures are analyzed and detected from sound data. In general, sound data at
the site classifies 

sounds of varying frequencies due to normal operation and
failure. 

Coefficients are extracted using FFT technique, and the decision is made
by discriminating normal and faulty features through 

advanced artificial
intelligence identification algorithms. 

The discrimination algorithm based on The
artificial intelligence finds the coefficient by learning the data of the
normal and 

abnormal motion in advance, and then performs the process of
extracting and discriminating the features of the measured 

data using the
learned coefficient in real time. The detection algorithm is performed by each detection
modules device installed 

in the field and the their results are transmitted to
the office in real time through the stable field network.

 3.     Benefits of using system

• It
performs early detection of defective rotors and conveyor idlers.

• It
can prevent expensive belt damage, fire prevention, hazardous site inspection
and repair.

• The
condition of the conveyor site can be monitored and operated remotely without
human intervention.

• It
can be applied to various conveyor systems and is easy to expand further.

• It
is reliable because it monitors remotely using an authorized network used in
the factory.

• Since
the sensing device uses an embedded system structure with an operating system
installed, it is easy to maintain the operating software.

4.     Product components

The system consists of 5 parts.

•  Detection module with microphone

•  DEVICENET and MODBUS communication
module

•  Network converter(Ethernet) gateway

•  Programmable Logic
Controller(PLC)

•  Human Machine Interface(HMI)

5.     Software

• The
artificial intelligence software installed on the detecting module has a
built-in fault decision algorithm 

and includes control functions of the module
operation. And it consists of an algorithm that gather signals 

from a
microphone and performs a preprocessing, and controls communication.

• PLC has
built-in software that receives data and transmits it to HMI, and user
environment is programmed in HMI. 

The data measured in the field is saved in general
file format to be used for later analysis.

6.     Product Support Plan

• POLTEC
is committed to supporting our customers at highest level in the market.

• Product
Support Plan (PSP) extends the standard product warranty for an additional
period, continuing unlimited access to 

technical support, global repair
coverage, and so on. We will upgrade the failure detecting functionality
continuously. 

​

​

​ 

1.     Introduction

In many
industries, power transmission rotors and transport conveyors are an important
part of material handling systems,

especially in the mining and cement
industries. That is why idler failures in conveyor systems can lead to belt
damage, cause fire, 

costly downtime and loss of production. 

To solve this
problem, POLTEC's rotating body and idler sound monitor device was developed to
detect defects in the rotating part

bearing and idler early. The POLTEC sound
monitor kit distinguishes between the sound of the idler that is operating
normally and 

the failure sound, and the maintenance worker can quickly and
safely detect the defective idler around the machine and conveyor belt 

without
having to do direct inspection at the site. 

Therefore, this equipment is used
to detect failures of rotating bodies such as motors and idlers, which are
configured on conveyors in 

industrial sites that transport coal or cement, and
can remotely detect failures of rotating bodies by configuring an automated
system.

Also, it can inform the user through the monitor screen. Unlike the
conventional method in which a person intervenes and directly 

approaches the
site to determine the failure of a motor or idler, a number of detection modules
are placed around the conveyor to be 

measured to check the failure in the
office.I

​

 In displaying result
information, it is divided into normal, caution, warning, and dangerous stages
according to the degree of failure, 

and the degree of failure according to the
frequency of occurrence can be displayed on the user's HMI monitor screen to
notify the administrator. 

These detector modules use a non-contact method using
sound, and are deployed around the rotating body or idler without contacting to
the 

motor or idler, so that the installation and maintenance is easy, and the remote
user can control the operation of the modules placed in the field. 

For example,
startup and shutdown can be selected, specific modules can be selectively
operated from multiple installed modules, and the site 

manager can remotely
restart the device or adjust the environment variables of the device using the
touch panel.

​

​The POLTEC system consists of a
detector module, communication gateway, PLC, and HMI device. 

the detector
module classifies the sound data with an artificial intelligence based on Deep
Learning algorithm, 

is configured to be connected to the PLC through an
industrial standard communication system, and effectively 

provide site
identification information to the remote users.

​

The information
in the HMI is as follows. First it shows the working status as a bar level
graph, allowing the user to 

easily understand the failure trend.

​

​

Second, it provides
a data accumulation graph. In the graph, the degree of failure is recorded at
regular intervals and 

displayed on the screen, so that the administrator can
monitor the trend of failures in one day or at a fixed time. 

And it is designed
to be able to store and store this information on the additional SD card.

​

​

Thirdly, the screen shows schematic diagram of the connection for the
modules installed on the site and the specific conveyor

line to enhance the
user's understanding, and marks the problem section of the motor or idler so
that the location of replacement 

and repair can be quickly identified.

​

​

Failure detection module of the
rotating body is a device that directly measures the failure by placing a
number of devices in the field. 

The measured result is transmitted to the
office by linking the information like DeviceNet, an industrial communication
protocol, 

and the module has a high sensitivity microphone and performs function
that analyzes sound information generated in the field 

up to 20 kHz, allowing
precise analysis of the sound in the field. 

​

2.     Failure detection method

Conveyor motor and idler
failures are analyzed and detected from sound data. In general, sound data at
the site classifies 

sounds of varying frequencies due to normal operation and
failure. 

Coefficients are extracted using FFT technique, and the decision is made
by discriminating normal and faulty features through 

advanced artificial
intelligence identification algorithms. 

The discrimination algorithm based on The
artificial intelligence finds the coefficient by learning the data of the
normal and 

abnormal motion in advance, and then performs the process of
extracting and discriminating the features of the measured 

data using the
learned coefficient in real time. The detection algorithm is performed by each detection
modules device installed 

in the field and the their results are transmitted to
the office in real time through the stable field network.

 3.     Benefits of using system

• It
performs early detection of defective rotors and conveyor idlers.

• It
can prevent expensive belt damage, fire prevention, hazardous site inspection
and repair.

• The
condition of the conveyor site can be monitored and operated remotely without
human intervention.

• It
can be applied to various conveyor systems and is easy to expand further.

• It
is reliable because it monitors remotely using an authorized network used in
the factory.

• Since
the sensing device uses an embedded system structure with an operating system
installed, it is easy to maintain the operating software.

4.     Product components

The system consists of 5 parts.

•  Detection module with microphone

•  DEVICENET and MODBUS communication
module

•  Network converter(Ethernet) gateway

•  Programmable Logic
Controller(PLC)

•  Human Machine Interface(HMI)

5.     Software

• The
artificial intelligence software installed on the detecting module has a
built-in fault decision algorithm 

and includes control functions of the module
operation. And it consists of an algorithm that gather signals 

from a
microphone and performs a preprocessing, and controls communication.

• PLC has
built-in software that receives data and transmits it to HMI, and user
environment is programmed in HMI. 

The data measured in the field is saved in general
file format to be used for later analysis.

6.     Product Support Plan

• POLTEC
is committed to supporting our customers at highest level in the market.

• Product
Support Plan (PSP) extends the standard product warranty for an additional
period, continuing unlimited access to 

technical support, global repair
coverage, and so on. We will upgrade the failure detecting functionality
continuously. 

​