Rotação da correia em transportadores tubulares: desenvolvimento de um índice de estabilidade e digitalização do monitoramento da posição de sobreposição

Abstract

Pipe conveyors provide an environmentally friendly alternative to open-troughed bulk solids conveyance, particularly for long or complex routing applications. However, the sustainability of this technology is compromised by unstable operations. Complex routing, operational variations, and environmental factors create uneven contact forces, triggering belt rotation. This is a critical failure mode that requires continuous monitoring throughout the conveyor’s lifecycle. Insufficient failure data represents a typical challenge for this application. In this study, the belt rotation failure mode was analyzed, and a linearized model of an overlap stability index was proposed to evaluate the resilience of the overlap position through a case study of a short-flight pipe conveyor. Using an Industrial Internet of Things network, a beltindependent measurement system with multiparameter capability was developed. Technological principles were hypothesized as the minimum requirements for enabling the scaling of belt-rotation monitoring in industrial applications. Enabling technologies were adopted to foster innovation, and a physical prototype was implemented to address data scarcity. The measurement results demonstrated suitable precision for digitization objectives: overlap angle (3.31 ± 16.76°), pipe diameter (+13.39 ± 7.21 mm), and overlap length (−26.28 ± 25.15 mm), based on 307 samples with a latency of 350.13 ms. The framework demonstrates potential for industrial deployment with acceptable performance for real-time monitoring.