Detection and Analysis of Conveyor Belt Damage: A Review of Sensing Technologies and Signal-Based Approaches

Conveyor belts constitute critical components of bulk material handling systems, and their reliable operation directly affects process continuity, operational safety, and maintenance costs in industrial environments. Increasing requirements regarding system reliability and predictive maintenance have stimulated the development of advanced diagnostic methods for conveyor belt condition monitoring. This review presents a comprehensive analysis of conveyor belt damage detection and diagnostic approaches, with particular emphasis on sensing technologies and signal-based methodologies. The paper discusses major conveyor belt degradation mechanisms and analyzes their representation in diagnostic data obtained using different sensing modalities. Current developments in machine vision systems, magnetic methods based on magnetic flux leakage, ultrasonic techniques, and X-ray imaging are critically reviewed together with signal preprocessing procedures, feature extraction strategies, and damage classification approaches. Particular attention is devoted to the transition from conventional signal processing techniques toward machine learning and deep learning methods enabling automated feature representation and fault identification. The analysis indicates that despite substantial progress in sensing technologies and artificial intelligence, most existing solutions remain strongly sensor-specific and limited to individual data modalities. Key research gaps include the lack of unified damage representation frameworks, limited benchmark datasets, and the insufficient integration of multimodal sensing information. Future progress will likely depend on the development of integrated diagnostic ecosystems combining heterogeneous sensing technologies, advanced feature representation methods, and intelligent decision-support systems.