Condition Monitoring System

Rexline’s Condition Monitoring System represents the very latest state-of-the-art in steel cord belt condition monitoring. The Condition Monitoring System uses a patented high-resolution Roller Transducer to detect belt carcass and splice damage. When employing highresolution Transducers to detect such damage, it is essential that the Transducer be as close to the cords as possible and that the belting be dynamically stable, vertically.


  • Broken cords
  • Rusted or corroded cords
  • Kinked cords (vertical plane)
  • Fatigued cords (if cords have discontinuity in filaments
    consistent with plastic deformation and ductile failure)
  • Missing cords
  • Splice anomalies, using magnetic signature comparison

Accurate location and quantification of damage is achieved without the need to stop the conveyor for visual inspection. The belt carcass is magnetized during scanning, leaving a magnetic ‘fingerprint’ in the belting, which aids in exact location of Events of Interest, if belt maintenance is needed. There is no limit to belt width, length, speed or product conveyed.

As well as data on demand, the Belt Scanner offers a 24/7 Disastrous Event Detection (DED) feature, where the belt condition is continuously monitored against a user-defined level of damage. If this level is exceeded, the conveyor can be stopped. A Programmed Parking option allows belt maintenance personnel to park the belting automatically where they want, for belt repairs etc., in a splicing station.




The Condition Monitoring System is a software-based device. All device configuration and operation is performed under proprietary software which runs on Windows 98 – Windows 8. Data Analysis software is available, which also runs on Windows.



The Condition Monitoring Roller Transducer is non-magnetic and is located in a flat section of belting, in contact with the Pulley Cover, where it is used to provide belt stabilization and to ensure minimum transducer-to-cord distance.



The 24/7 version of the Belt Scanner employs a Main Electrical Enclosure (MEE), which consists of a stainless steel
enclosure (IP69K), containing the system power supply, electronics and communication module. The MEE communication module allows connectivity with the system, either at short range via serial or Ethernet data cables, or long range over the Internet via a Mobile Broadband service, or site LAN via VPN.

It is strongly recommended that the MEE be located inside an electrical substation or similar building, away from direct sunlight and wash down. Where this is not possible, integrated weather shields can be built onto the enclosure.



The Condition Monitoring equipment requires very little maintenance other than general housekeeping by ensuring the system is kept relatively free from product build-up etc.

Visual inspection should be carried out on a regular basis to confirm all mounts are secure. Light hose down is recommended on a regular basis. The Roller Transducer needs to be checked regularly to ensure it is still in intimate contact with the belting. Build up of product on the Roller Transducer will degrade the data quality.


Technical specifications vary with each system supplied, therefore the values shown below are for a typical system.

Construction – Stainless Steel
Dimension – 140.0 (Dia) x 1,500 (L) mm *
Net Weight – 60kg*
Operating Temp – 13 ~ 158°F(-25 ~ 70°C), 5 to 95% RH
Storage Temp – 40 ~ 176°F(-40 ~ 80°C), 5 to 95% RH
MAGNET BAR (per each)
Construction – Stainless Steel
Dimension – 40.0 (H) x 40.0 (W) x 1,500 (L) mm*
Net Weight – 9kg*
Operating Temp – 13 ~ 158°F(-25 ~ 70°C), 5 to 95% RH
Storage Temp – 40 ~ 176°F(-40 ~ 80°C), 5 to 95% RH
Construction – Stainless Steel IP69K
Dimension – 400 (H) x 400 (W) x 250 (D) mm
Net Weight – 20kg*
Power Supply – 110 / 240 VAC 50 / 60Hz or 24 VDC
Power Consumption – 10W
DED Output – Relay, Form C – 5A 240 VAC
Relay Action – N.O.

* varies from system to system.

Related Posts