When testing steel cables in conveyor belts, a magnetic resonance method reaches its limits. A mobile X-ray system was able to help Vulkanisiertechnik Mahnke GmbH with extensive analyses.
At the end of 2020, a steel cord belt of a conveyor system ran backwards down the conveyor bridge while the belt was being changed and “piled up” on the conveyor system. A magnetic resonance method was used to check the condition of the steel cables, but the results were only quantitative, i.e., not enough information to determine the inherent quality. More precisely, three large suspicious areas, as well as about 30 other small potential damages, were detected. However, due to the technology on hand, combined with external disturbances, it was not possible to clearly determine whether the steel cables were torn or crushed. In addition, the results were not reproducible due to the prevailing environmental influences. Mahnke was looking for a dependable solution, that would deliver absolutely reliable results. One idea was an inspection with a mobile X-ray system.
That is why Mahnke approached VisiConsult -the family company from Northern Germany and world market leader for the manufacturing of innovative X-ray solutions.
Figure 1: The mobile X-ray system Xplus Mobile
First, a reference section was sent to VisiConsult and examined under laboratory conditions. Benjamin Wielgosch, Head of Application, knows the flexible application possibilities of X-ray technology: “X-ray technology is the ideal technology to make the invisible visible. At VisiConsult, we achieve this through a variety of solutions. From portable mobile systems to complex CT systems. The systems are easy to use and users get results quickly.” Shortly after the investigation, an on-site visit was finally held at the Mahnke factory.
Figure 2: Xplus Mobile in action. Areas of interest have been marked on the conveyor belt; the X-ray tube is shooting down from above
The system had to be set up on short notice. The X-ray method clearly showed the structure of the steel cables with a very high resolution, and the X-ray analysis was able to rule out breaks, tears or even warping of the steel cables at all detected points.
Figure 3: The steel cables inside the conveyor belt are clearly visible.
For this application, an Xplus Mobile System consisting of a digital detector and a portable X-ray tubewas used to visualize the steel inside of the conveyor belt.
Due to image filters, details of the individual wire ropes can be made even more visible. Sven Gross, authorized signatory at Mahnke, is enthusiastic: “Under difficult conditions it was possible to create absolutely high-resolution images. So, we’re pretty excited. We see a huge potential in performing condition monitoring of large, especially non-redundant conveyer belts”.
Figure 4: The cut steel cable ends and transverse reinforcement are clearly visible.
