Understanding Size Ranges in Conveyor Belt Analysis

How Low Can you Go?

One of the most common questions we receive is, “How small can you analyze?” The answer depends on multiple factors, but with the right imaging, WipWare’s systems can measure down to micron levels. However, when analyzing material on conveyor belts, additional considerations impact the minimum particle size that can be accurately measured.

Over the years, we’ve worked with a vast range of conveyor belt applications from highly quality-controlled 10-inch belts to massive run-of-mine conveyors in global copper, iron ore mine operations. Our fully adjustable frames are customized before shipping to ensure seamless integration into your operation.

Key Considerations for Conveyor Belt Analysis

When it comes to analyzing material on conveyor belts, a few fundamental factors come into play:

1. Fixed Camera Position – The camera is mounted at a consistent distance from the belt, usually within inches or millimeters.
2. Controlled Lighting – Conveyor belt environments generally offer stable lighting conditions, improving image accuracy.
3. Material Spread – The material stream typically covers a predictable portion of the belt, aiding in accurate analysis.
4. Optimizing Camera Placement – If you only have one camera installed, there’s likely room for more additional cameras can further refine your process.

With these stable conditions, WipWare’s systems can precisely determine the size ranges they analyze for each application. Let’s explore two real-world examples:

• Copper Operation ABC: A 10ft (~3000mm) conveyor belt used in a post-primary crushing application.
• Gold Operation XYZ: A 4ft (~1200mm) conveyor belt feeding a SAG mill.
• Height Matters: System Placement on the Conveyor Belt.
• At Copper Operation ABC, the conveyor’s width requires the particle sizing system to be mounted higher to capture the full material spread. This setup means the system focuses more on coarser size fractions. If a 10ft belt is in use, it’s unlikely that 100% fines are being transported.
• Using WipWare’s Camera Selection Matrix, we find that with a 1.2MP camera, the system can analyze material sizes ranging from 7.14mm (0.2813 inches) to 609.60mm (24 inches).
• In contrast, Gold Operation XYZ deals with already-crushed material, meaning the belt carries smaller particles. Since the camera is positioned closer, the system can analyze down to 2.86mm (0.1125 inches) and up to 243.84mm (9.6 inches) with a 1.2MP camera.

Expanding the Size Range: What are the options?

If you need to adjust the minimum or maximum detectable particle size, consider the following:

• Upgrade to a 5.0MP camera – Many clients opt for this to extend their minimum size detection capabilities.
• Reduce the Field of View – Narrowing the system’s focus enhances fine material analysis. However, doing this too aggressively may limit the ability to capture coarser size fractions.
• Tailored Solutions for Your Operation

If you’re wondering how effective an online analysis system would be for your conveyor belt, reach out to us! Our technologies have helped mining operations worldwide achieve better process control.

Have a unique application? We love a challenge—send us the details, and we’ll be happy to assist!