Conveyor Intelligence Platform
Know what is happening on your conveyor before it becomes a problem
Computer vision monitoring for conveyor belt integrity
Ore particle size and foreign object detection
Running continuously, without manual inspection.
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THE CHALLENGE
The risks that are difficult to see
until the damage is done
until the damage is done
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Catastrophic downtime from belt failure
A single longitudinal belt tear can cause an unplanned outage of up to 48 hours. Repairs run into hundreds of thousands of dollars — before counting lost production. -
Foreign objects reaching downstream equipmentRebar, timber, and oversized rock travel undetected until they reach crushers and liners, accelerating wear on equipment that is expensive to replace. -
Manual inspection is not enoughManual belt inspections are infrequent, inconsistent, and put personnel in proximity to moving machinery. They do not scale across a large conveyor fleet. -
Crushing circuit running on estimatesWithout accurate, real-time particle size data, feed sizing is reactive, not optimised. The crushing circuit never operates at its true potential.
CORE SOLUTION MODULES
Three monitoring functions.
One continuous system.
One continuous system.
01 Belt Condition Monitoring
Detects damage as it develops, not after it fails.
- Defect detectionIdentifies longitudinal tears, cuts, delamination, holes, and edge damage automatically.
- Splice integrity monitoringMonitors splice wear in real time — including rivet counting and photo-documentation — with degradation tracked over time.
- Geometry and alignmentDetects belt misalignment, idle running, and speed deviations.
- Remaining useful life forecastPredicts splice and belt segment life, enabling planned maintenance rather than emergency response.
- Precise defect localisationPinpoints each defect as an exact distance from a fixed reference point using belt travel encoders.
02 Granulometry Analysis
Measures ore particle size distribution directly on the belt, continuously.
- Real-time size classificationClassifies ore into defined size ranges — e.g., 0–5 mm, 5–10 mm, 10–15 mm, 15+ mm — updated continuously.
- Statistical reportingGenerates particle size distribution charts, weighted average calculations, and trend reports by shift.
- Crusher optimisation feedProvides data for automatic crusher gap adjustment — proven to increase crusher productivity by up to 10%.
- SCADA / MES exportExports granulometric data to process control systems via standard industrial protocols.
03 Foreign Object Detection
Stops tramp material before it reaches downstream equipment.
- AI-powered object recognitionDetects rebar, timber, oversized rock, plastic, and other non-ore material on the belt as it passes the camera.
- Semantic segmentationDeep learning accurately outlines hazardous objects under dust, partial occlusion, and variable lighting conditions.
- Instant operator notificationNotifies operators immediately on detection — before the object reaches a crusher or transfer point.
TECHNOLOGY
Built for the conditions
found in operating mines
found in operating mines
BUSINESS IMPACT
What changes at your operation
Results based on field deployments across operating mine sites.
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+10%
Increase in crusher productivity
Through continuous feed size optimisation
Granulometry module
-
-6%
Reduction in annual conveyor repair time
Through predictive belt condition monitoring
Belt condition module
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2 hours
Saved per conveyor per day
By eliminating manual visual inspections
All modules
-
48-hour outage
Becomes scheduled replacement
Reduced probability of catastrophic belt failure through continuous splice and belt health tracking.
Belt condition module
FAQ
Common questions
Yes. The cameras operate in IP67-rated housings with automated air-knife cleaning. The AI models are trained specifically on dusty, low-light, and wet-belt conditions — not on clean laboratory footage.
Yes. The system supports OPC-UA, Modbus, and REST API, with ready-made connectors for standard SCADA, MES, and ERP platforms.
A belt travel encoder synchronises the video stream with the physical position of the belt. Every defect is reported as a precise distance from a fixed reference point — so maintenance teams go directly to the right location.
See it running on a live conveyor
Request a demo and we will walk you through detection in real operating conditions — belt defect localisation, particle size output, and foreign object alerts.
