Business Scenario
Real-time material flow monitoring and anomaly warning for the belt conveying system of a thermal power plant's coal handling system.
As a key regional energy supplier, the customer is responsible for stable power and heat generation. With growing production scale, the coal conveying system must run continuously at high load, demanding higher equipment safety and maintenance efficiency. Traditional manual inspection cannot provide real-time awareness across the whole conveying process, especially in dusty, high-load environments where potential anomalies are hard to detect in time. The customer therefore sought digital monitoring to raise the intelligent management level of the coal handling system.
Customer Challenge
1. The long-running coal conveying system has delayed anomaly detection and difficult timely plugging risk control.
2. Heavy dust on site limits manual inspection coverage and poses safety risks.
3. No real-time material flow monitoring; operation status relies mainly on operator experience.
4. System upgrades must run without production stoppage.
Solutions
Deployed a belt material-flow LiDAR monitoring system using non-contact 3D sensing for real-time monitoring of the coal conveyor belt. The system fuses LiDAR and camera data to continuously capture material distribution on the belt, identifies abnormal conditions through data analysis, and helps operators detect potential risks early, shifting from reactive handling to proactive prevention.
Case Value
1. Non-contact monitoring: LiDAR captures material flow without touching the material, avoiding any impact on the existing conveying process.
2. Adapted to harsh industrial environments: the system features equipment protection and operational safeguards for dusty coal conveying sites.
3. Real-time sensing with early warning: continuous material flow data helps detect abnormal trends early and reduces the risk of sudden failures.
4. Centralized visual management: a large-screen platform displays equipment status, material flow and alarms to improve maintenance efficiency.
After implementation, the customer achieved digital monitoring of the coal conveying system, improving anomaly risk detection and providing data support for building an unmanned inspection system; operation and maintenance shifted from manual inspection toward data-driven proactive management.