Abstract
This paper presents the design, implementation, and testing of an advanced conveyor belt surface monitoring system, specifically engineered for harsh and complex industrial environments. The system integrates multiple cutting-edge technologies, including programmable logic controllers (PLC), laser scanning, industrial-grade cameras, and deep learning algorithms, particularly YOLOv7, to achieve real-time, high-precision monitoring of conveyor belt conditions. Key innovations include optimized detection location based on failure modes, advanced PLC integration for seamless automation, and intelligent dust-proof features to maintain accuracy in challenging conditions. Through strategic placement of detection devices and multi-mode control strategies (local, remote, and automatic), the system offers unparalleled adaptability and responsiveness. The system leverages robust data management for trend analysis and predictive maintenance, enhancing operational efficiency. The hardware architecture comprises PLC-based control systems, high-resolution industrial cameras, and laser emitters, while the software features a two-tier structure combining human-machine interaction (HMI) with real-time data processing capabilities. Experimental results show that the system is highly effective in detecting common belt defects such as foreign objects, tears, and shallow scratches, ensuring optimal operational efficiency and minimizing downtime. The system's scalability, robust data management, and adaptability to low-light and dusty conditions make it ideal for deployment in large-scale industrial operations, where continuous monitoring and early fault detection are critical to maintaining productivity and safety.