Innovative Diagnostics for Efficient Industry
MINING SUCCESS OF THE YEAR!
The DiagBelt+ system was recognized in the prestigious “Mining Success of the Year 2025” competition in the Innovation category.
The award was granted by the Mining Chamber of Industry and Commerce as an acknowledgment of a breakthrough solution supporting the diagnostics of conveyor belts.
During the official gala held at the Silesian Philharmonic in Katowice, the award was received on behalf of the team by Assoc. Prof. Ryszard Błażej, DSc, Eng., who led the implementation of the system at Bełchatów Lignite Mine (KWB Bełchatów).
Precision in motion
DiagBelt utilizes 90 inductive sensors spaced 25 mm apart, ensuring continuous and precise measurement of changes in the magnetic field occurring at locations of discontinuities in the core cords.
Resistance to Conditions
The design of the measurement head and conditioning strips allows the DiagBelt system to be installed on any flat section of the conveyor belt, ensuring reliable operation in challenging industrial conditions
Analysis and Reporting
Thanks to advanced software, it is possible to generate a comprehensive set of statistics, providing insights into essential parameters.
DiagBelt: Power of Measurement in Motion
DiagBelt+: An innovative diagnostic device for the industry, designed to assist in the precise and non-invasive assessment of the technical condition of conveyor belts with steel cables. With 90 inductive sensors, it provides a transverse resolution of 25 mm and a longitudinal resolution of 2.5 mm at a belt speed of 1 m/s. The device allows real-time monitoring of belts, generating detailed statistics. It automatically detects core damage, precisely locating them along the length and width of the belt. This tool facilitates informed decisions regarding the need for replacement or repair of conveyor belts, contributing to the efficient maintenance of industrial operations. DiagBelt+ is a comprehensive solution that enhances the quality of diagnostics and supports the optimization of maintenance activities for conveyor belts.
Magnetic method in assessing the technical condition of the core
DiagBelt+ is a diagnostic system for conveyor belts based on magnetic technology. It consists of a measuring head, two heads of permanent magnets, a tachometer, and a data acquisition module. The measuring head contains 90 coils spaced every 25 mm, allowing precise recording of changes in the magnetic field. The system software enables data recording, export, and comprehensive analysis of the conveyor belt core’s condition.
Magnets on both sides of the belt magnetize the steel cables in the core during belt movement. The measuring head, equipped with inductive coils, records changes in the magnetic field caused by damage to the cables, such as breaks, cuts, or corrosion. Measurement signals are processed, thresholded, and stored as discrete values.
DiagBelt+ stands out with the ability to identify individual cable failures, a feature rarely achievable in traditional systems. Thanks to the magnetic module, the system precisely locates each damage, enabling effective diagnostics of conveyor belts with steel cables.
Diagbelt - Precise diagnostics of conveyor belts
DiagBelt+ is an innovative diagnostic system that facilitates the assessment of the technical condition of conveyor belts with steel cables. Its advantages include the ability to conduct examinations on conveyors without the need to stop or empty them of material.
Automatic detection of connections and their storage in a database allows for individual interpretation, as well as precise determination of the geometry of the connection and comparison with a reference connection. Additionally, the system automatically calculates the wear degree of St-type belt cores, counts the number and area of failures, and users can define threshold values generating warnings about the belt’s condition.
An undeniable advantage is DiagBelt’s ability to generate alerts about potential threats to the continuity of the conveyor system’s operation. By providing a precise assessment of the technical condition of conveyor belts and allowing the selection of an optimal replacement time, the system supports making better decisions regarding repairs and belt replacements. As a result, there is the potential for significant cost savings by eliminating subjective and imprecise decisions based solely on visual assessment and knowledge of the belt’s age.
Operational Program Smart Development
he Operational Program Smart Development (POIR) is the largest research, development, and innovation funding program in the European Union, financed from structural funds and the second-largest national program for the years 2014-2020.
The project is implemented in a Consortium, composed of PGE GiEK S.A. (leader) and Wroclaw University of Science and Technology (Partner).
Get to know our team
The DiagBelt+ project is the result of collaboration between PGE GiEK S.A. and Wroclaw University of Science and Technology. On the Consortium Leader’s side (PGE GiEK S.A.), the project involved a team led by Zbigniew Konieczka, contributing valuable industry expertise. On the Partner’s side (Wroclaw University of Science and Technology), the project was executed by a team jointly led by Professor Anna Burduk and Professor Ryszard Błażej. This collaborative effort from both sides makes the DiagBelt+ system a comprehensive diagnostic tool, offering innovative solutions for the mining sector
Professor at the Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology.
For over 30 years, he has been affiliated with the Belt Conveying Laboratory, where he serves as Technical Manager and conducts research on the diagnostics of conveyor belts and their joints. His expertise focuses on non-invasive methods for monitoring the technical condition of belts and the development of intelligent diagnostic systems.
He is the author or co-author of seven patents and four patent applications, over 130 scientific publications, and has participated in eight research projects that have contributed to the implementation of modern technologies in the conveyor transport industry.
He has collaborated with leading international companies, including Continental, Semperit, Dunlop, BeltGuard, and Goodyear, and has been involved in projects such as DiagBelt, BeltSonic, HRDS, and NZTP.
Systems developed under his leadership — including DiagBelt+, implemented at Bełchatów Lignite Mine (KWB Bełchatów) — have enabled longer belt service life and significant operational cost savings.
He is currently developing an innovative device for detecting longitudinal cuts in conveyor belts and for diagnosing vulcanizing presses used in industry. He actively integrates modern predictive diagnostics methods with practical industrial applications.
Professor at the Department of Mining, Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology.
He graduated from the Faculty of Fundamental Problems of Technology, majoring in Mathematics.
In 1996, he defended his doctoral dissertation entitled “A Method for Determining the Operating Time Distribution of a Conveyor Belt and Its Application in Belt Lifetime Forecasting.”
In 2007, he obtained his habilitation (DSc) in technical sciences, specializing in mining and geological engineering.
Research and teaching assistant at the Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology.
She specializes in diagnostics of conveyor belt damage using artificial neural networks and in measurement data analysis.
She has teaching experience in programming and data analysis and holds AGILE and PRINCE2 Foundation certifications, as well as electrical qualifications up to 1 kV.
She is an active member of the Association of Polish Electrical Engineers (SEP).
Employed at the Wrocław University of Science and Technology since 2004, he has been an active member of the Accredited Belt Conveying Laboratory, participating in numerous research and teaching activities.
His contribution to over 70 diploma theses and involvement in various projects funded by the Ministry of Science and Higher Education (MNiSW) form the foundation of his professional experience.
He has received the Rector’s Award of Wrocław University of Science and Technology for his scientific and teaching achievements and successfully collaborates with industry on practical projects – including the development of an eco-friendly technology for conveyor belt splicing.
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Wrocław University of Science and Technology,
Faculty of Geoengineering, Mining, and Geology
Department of Mining
ul. na Grobli 15, 50-421 Wrocław, Poland - Ryszard Błażej
- ryszard.blazej@pwr.edu.pl
- +48 71 320 49 00