The hidden threat of conveyor belt bearing failures
It’s said that the smallest elements can have the greatest impact. This lesson is illustrated by a famous moment during a rehearsal with Sir John Barbirolli, conductor of the world-renowned Halle Orchestra. He shouted, “Where’s the piccolo?”—a tiny instrument that, despite its size, was crucial to the performance. This anecdote resonates within industrial operations too, where seemingly insignificant components, like roller bearings in conveyor belts, can bring entire production systems to a halt if they fail.
Consider a quarry, where mined aggregate is conveyed via conveyor belts to a ship or loading point. These massive belts are supported by roller bearings, often overlooked in comparison to larger machinery like crushers and gearboxes. However, when these bearings seize or fail, the entire conveyor system can come to a grinding stop, halting production and costing valuable time and money.
One of the largest conveyor belt systems in the world, the 31-kilometre-long conveyor between Mount Saddleback mine and Worsley refinery in Australia, carries 2,700 metric tonnes of bauxite ore annually. Despite the scale of such operations, the health of the bearings is critical. Identifying early signs of failure can prevent catastrophic downtime.
Thermal imaging cameras have long been used to spot potential bearing failures, saving millions in production costs. But newer technologies, such as the FLIR Si2 LD acoustic imaging camera, offer even earlier warnings. Its Mech Mode detects mechanical issues with bearings and gears before they fail, making it easier to conduct regular, detailed health checks on extensive conveyor systems. With capabilities like 2x and 8x digital zoom, GPS tagging, and cloud storage, this advanced tool helps identify problems early, reducing downtime and maintenance costs, and ultimately keeping production running smoothly.

The health of the bearings is critical. Identifying early signs of failure can prevent catastrophic downtime

Acoustic imaging cameras can offer early warnings

Capabilities include 2x and 8x digital zoom, GPS tagging, and cloud storage