A New Embedded Condition Monitoring Node for the Idler Roller of Belt Conveyor

The idler roller is the bearing device of the belt conveyor, whose health status is crucial for the efficient transportation of materials in coal mines and other industries. In this article, we propose a new embedded belt conveyor idler-monitoring node with the capacities for self-powering, multiparameter sensing, and wireless communication for the real-time health monitoring of the idler roller. First, the architecture of the belt conveyor idler-monitoring network was proposed, and three functional modules were designed for the node: an energy-harvesting module based on the Halbach permanent magnet array, an energy-management module that adapts the energy harvester to the node’s power consumption, and a control/sensing module that employs wireless communication. Subsequently, the performance of the node was tested and analyzed. The power of the energy harvester designed here was 171.33 mW, which sufficiently provides for the node’s power consumption. The energy management circuit can provide the network with a remaining operating time of 74 min. The communication test showed the influence of narrow space on the reliable communication distance of the nodes. Concluding the research, an overall test of the node was conducted, demonstrating that the node can accurately collect and transmit temperature and vibration data pertaining to the idler, meeting the monitoring requirements. The proposed node provides a technical solution for the health monitoring of belt conveyor idlers and the overall system.