Design of Online Monitoring and Fault Diagnosis System for Belt Conveyors Based on Wavelet Packet Decomposition and Support Vector Machine

Belt conveyors are the equipment widely used in coal mines and other manufacturing factories, whose main components are a number of idlers. The faults of belt conveyors can directly influence the daily production. In this paper, a fault diagnosis method combining wavelet packet decomposition (WPD) and support vector machine (SVM) is proposed for monitoring belt conveyors with the focus on the detection of idler faults. Since the number of the idlers could be large, one acceleration sensor is applied to gather the vibration signals of several idlers in order to reduce the number of sensors. The vibration signals are decomposed with WPD, and the energy of each frequency band is extracted as the feature. Then, the features are employed to train an SVM to realize the detection of idler faults. The proposed fault diagnosis method is firstly tested on a testbed, and then an online monitoring and fault diagnosis system is designed for belt conveyors. An experiment is also carried out on a belt conveyor in service, and it is verified that the proposed system can locate the position of the faulty idlers with a limited number of sensors, which is important for operating belt conveyors in practices.