Frequent and accurate inspections of industrial components and equipment are essential because failures can cause unscheduled downtimes, massive material, and financial losses or even endanger workers. In the mining industry, belt idlers or rollers are examples of such critical components. Although there are many precise laboratory techniques to assess the condition of a roller, companies still have trouble implementing a reliable and scalable procedure to inspect their field assets. This article enumerates and discusses the existing roller inspection techniques and presents a novel approach based on an Unmanned Aerial Vehicle (UAV) integrated with a thermal imaging camera. Our preliminary results indicate that using a signal processing technique, we are able to identify roller failures automatically. We also proposed and implemented a back-end platform that enables field and cloud connectivity with enterprise systems. Finally, we have also cataloged the anomalies detected during the extensive field tests in order to build a structured dataset that will allow for future experimentation.

Technological advances have opened up the possibility of using unmanned aerial vehicles (UAVs) in diverse environments. The mining industry has been looking for solutions to handle periodic inspections of the belt conveyors that transport iron ore. The state of the art indicates the use of UAVs for this task as an attractive, low-cost and safe alternative, allowing for a significant increase in security. A new concise mixed-integer linear programming (MILP) model is developed to address UAV routing and charging station planning for belt conveyor inspection. We conduct computational tests covering a real conveyor belt system in Brazil to validate the model in practical applications. The loading terminal possesses approximately 120 km of belt conveyors, leading to 230 inspection points. Instances of different sizes were generated by randomly sampling a subset of these points and using two different drone specifications. The results show that the new optimization modeling satisfies the problem requirements and is a significant contribution to the automation of inspection in the mining industry.