Conveyor Belt Thickness Measurement Systems and Methods for Detecting Changes in Conveyor Belt Thicknesses Laser-Based 3D Wear Monitoring for Heavy Industrial Belts

This patent describes a method for measuring conveyor belt wear by projecting a laser pattern onto the belt surface, building a three-dimensional model of the belt during one operating cycle, repeating the measurement during a later cycle and detecting differences in position data that exceed a configurable threshold. The system gives mine, port and bulk-handling operators an automated, quantitative view of belt thickness over time.

The Problem

Heavy-duty conveyor belts are critical infrastructure across mining, ports, power generation and bulk handling. A belt failure typically takes a production line down for hours, and severe wear can lead to safety incidents. Belt condition has historically been monitored by visual inspection and periodic manual thickness measurements at fixed points, both of which miss localised wear patterns and depend on the inspector being present. Various ultrasonic and magnetic systems have appeared, but each has limitations on belt material, cover type and resolution. A method that delivers a full surface map of the belt automatically, and tracks how that map changes between operating cycles, would close most of those gaps.

What This Invention Does

The patent describes a method in which a laser comprising a plurality of laser points is emitted onto the surface of a conveyor belt. During a first cycle of the belt, the system captures a plurality of first images of the belt surface and uses them to construct a first three-dimensional image, with first position data assigned to each of many surface locations. During a later cycle, a second set of images yields a second three-dimensional image with second position data at the same locations. The system then determines whether the difference between the first and second position data exceeds a predetermined threshold, flagging wear or other change.

The disclosure covers the laser projection arrangement, the imaging and 3D reconstruction pipeline, the difference computation and the use of thresholds to trigger alerts or maintenance actions.

Key Features

• Multi-point laser projection. A laser pattern with multiple points provides a dense set of measurement locations across the belt surface rather than a single line.
• Per-cycle 3D reconstruction. Each pass yields a complete three-dimensional snapshot of the belt rather than a single thickness reading at one point.
• Change detection between cycles. The system compares 3D snapshots from successive cycles, exposing wear patterns and progression over time.
• Configurable threshold logic. Operators can set the position-data difference threshold that triggers alerts, matching the sensitivity to belt type and risk tolerance.
• Non-contact, continuous monitoring. Laser-based measurement avoids the need for contact sensors or manual inspection, supporting automated operation in remote installations.

Who Is Behind It

The applicant is Martin Engineering Company, a long-established Illinois-based supplier of bulk material handling equipment, conveyor belt accessories and cleaning systems used worldwide in mining, cement, power and aggregate operations. The named inventors are Italo Andrade, Henrique Canaverde, Luiz Machado and Paul Harrison. The Australian patent attorney of record is listed on the title page.

Why It Matters

Australia is one of the world’s largest mining economies and operates some of the longest and most heavily loaded conveyor belt systems anywhere, particularly in iron ore, coal and bauxite. Predictive belt-wear monitoring is squarely on the agenda for major operators looking to reduce unplanned downtime and improve worker safety by removing manual inspections from hazardous zones. A patent on the underlying laser plus 3D plus change-detection method positions Martin Engineering to compete on a high-value condition-monitoring capability in a market where the company already has a significant installed base.

Related Concepts

• Conveyor belt – the equipment being monitored.
• 3D scanning – the broader category of measurement technology in use.
• Structured light – a related laser-projection approach commonly used in industrial metrology.
• Predictive maintenance – the operational discipline this measurement feeds into.
• Mining – the end-use industry that has the largest exposure to conveyor reliability.

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AU 2026201890 was published in the Australian Official Journal of Patents on 2 April 2026 and is open for public inspection. Patent applications represent inventions that are sought to be protected and do not necessarily reflect commercially available products.