Due to increasing demands for ensuring the safety and reliability of a system, fault detection (FD) has received considerable attention in modern industries to monitor their machines. Bulk materials are transported worldwide using belt conveyors as an essential transport system. The majority of conveyor components are monitored continuously to ensure their reliability, but idlers remain a challenge to monitor due to the large number of idlers (rollers) distributed throughout the working environment. These idlers are prone to external noises or disturbances that cause a failure in the underlying system operations. The research community has begun using machine learning (ML) to detect idler’s defects to assist industries in responding to failures on time. Vibration and acoustic measurements are commonly employed to monitor the condition of idlers. However, there has been no comprehensive review of FD for belt conveyor idlers. This paper presents a recent review of acoustic and vibration signal-based fault detection for belt conveyor idlers using ML models. It also discusses major steps in the approaches, such as data collection, signal processing, feature extraction and selection, and ML model construction. Additionally, the paper provides an overview of the main components of belt conveyor systems, sources of defects in idlers, and a brief introduction to ML models. Finally, it highlights critical open challenges and provides future research directions.

A microcontroller-based conveyance system using a hybrid electromagnetic suspension (EMS) system and a linear synchronous motor (LSM) is proposed. Unique placements of the hybrid EMS and LSM integrated with an array of infrared sensors, embedded microcontroller, and electronics switching circuits are designed to maintain the air gaps and the propulsion. To improve the air-gap stability, a robust sliding-mode feedback controller is used. The entire control system is implemented, simulated, and verified by experimental measurements. As compared to different control schemes such as the H-infinity and the proportional-integral-derivative controller, it has shown to give reasonable performance under certain parametric uncertainties.