Wear intensity evaluation in conveying systems – An acoustic emission and vibration measurement approach

Abstract Conveying raw materials is essential in heavy industries and mostly accompanied by wear. Impinging of materials cause energy transfer, generating elastic waves. In this work, an acoustic emission (AE) measurement system and an accelerometer for vibrations were utilised to assess different wear phenomena. A 3-fold approach was undertaken: i) identification of characteristic acoustic damage features in a model impact-test; ii) impact tests with raw materials on wear plates in lab-scale; iii) field test of the measurement systems in the harsh environment of a steel plant. Results showed clear frequency changes with decreasing plate thickness. Micro-cracking was indicated by high frequencies, showing the first stage of wear. AE and vibration measurements distinguished raw materials clearly in both, close-to-reality and field testing.