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Currently, ports generally use belt conveyors to transport coal. During transportation, longitudinal tearing of the belt is a highly destructive form of damage. In severe cases, an entire belt worth over a million dollars can be rendered unusable; there have been incidents of this kind in ports, steel mills, power plants, and mines. During the operation of the conveyor belt, there is a vertical drop at the junction of two consecutive circular conveyor belts. The starting end of the subsequent conveyor belt is subjected to the strong impact force caused by the coal flow falling from the end of the previous conveyor belt. When foreign objects such as iron pieces, stones, and wood fragments are present in the coal, the damage caused to the conveyor belt can be even more severe. Once a tearing accident occurs, it will result in significant economic losses, and sometimes even force the entire production process to come to a halt. Such phenomena occur in almost every port; they have become one of the most worrying, troublesome, and yet unresolved problems for ports. Therefore, studying tape tear protection and prevention has become an important issue for the safe operation of port equipment. During transportation, the conveyor belt’s rubber strip tends to tear along its longitudinal direction. Therefore, the reasons for such longitudinal tearing of the belt are analyzed as follows: 1. Tearing caused by belt misalignment. During belt operation, when the belt shifts significantly to one side, folds or accumulations of folds form on that side; as a result of uneven pulling forces, or due to being pinched or scratched, tears can occur. Since it takes a process to reach the point of tearing, and the phenomenon is quite obvious, it is easy to observe. Adjust promptly if the belt is found to be misaligned. Ensuring that the deviation switch functions properly can prevent such tearing accidents from occurring. 2. Core pulling and tearing (occurs only in steel cord conveyor belts). Under severe impact forces, the belt can sometimes cause the steel wires within it to break, as a result of prolonged exposure to forces such as friction, pressure, bending, and pulling. The broken end of the wire rope will protrude beyond the cover rubber at the belt joints, adhesive seams, or areas with severe wear. When the exposed steel wire rope reaches a certain length, it may get entangled in drums, idlers, etc. As the belt moves, the steel wire rope is pulled out of the rubber covering on the belt, causing tears; or the scraper of the belt cleaner may catch onto the metal wires or other debris on the belt surface, wearing through the belt. To prevent such tears, it is necessary to intensify inspections and address belt holes and exposed wire rope ends promptly. 3. Material or debris gets jammed, blocked, or torn. This situation occurs at the junction of the funnel and the feed chute. Due to the limited distance between the lower front edge of the funnel and the belt surface, as well as the spaced arrangement of the buffer idlers beneath the belt, the natural load-bearing capacity is uneven. When the length of the materials or impurities being transported exceeds this distance, under certain conditions it is easy for large pieces of material to get stuck between the front edge of the funnel and the belt, causing intense pressure on the belt and leading to its tearing. 4. Scratches from foreign objects. This type of damage often occurs at the lower part of the funnel and is one of the most common types of belt injuries; there are two scenarios in this case. The first is pressure-induced scratches from long, rod-shaped sharp objects. When the longitudinal dimension of the foreign object entering the lower opening of the funnel is greater than its capacity to pass through, the object gets stuck at the bottom of the chute. Pressure is generated by the forward movement of the belt, thereby scratching it. The second is penetration scratches caused by sharp objects. As required by the process, there must be a certain spatial difference at the connection points between the two belts; this creates a certain amount of potential energy in the material on the upper belt, which allows it to acquire a certain speed when it falls onto the lower belt. If a sharp object accidentally gets mixed into the material, upon contact with the belt, due to inertia, the lower part of the sharp object penetrates the belt and gets stuck on the idler roller, while the upper part is blocked by the front edge of the chute, thus forming a sharp blade that causes tears in the belt as it moves forward. Third are other scratches, such as damaged idler rollers and welded cracks in the end caps. In summary, longitudinal tearing of the belt occurs mainly at the material discharge point at the rear of the machine. Analyzing the causes of such tearing, it can be seen that the reasons for severe belt tearing are quite complex; therefore, multiple detection devices need to be used simultaneously to ensure effective protection. Research on tape protection devices at home and abroad has evolved from contact-based to contactless methods, and from simple designs to intelligent systems. The main inspection methods for protective devices include radiographic testing, ultrasonic testing, and electromagnetic testing, etc. However, these inspection methods have drawbacks such as high costs, complex maintenance, and limited capabilities in detecting different types of tears. In light of this, a comprehensive anti-tear protection device is designed based on the different types of tears that occur on site, so as to carry out appropriate inspections corresponding to the various causes and consequences of these tears. This helps to avoid incomplete detection resulting from a single detection method, as well as prevent tearing. If a belt tear has already occurred, the belt can also be repaired in order to prevent the tear from worsening, while also saving some of the costs associated with replacing the belt. Currently, the use of polyurethane elastomer wear-resistant materials for belt repair through spraying is common both domestically and internationally. This spraying method allows the polyurethane to blend effectively with the belt material, thereby extending the belt’s service life without affecting its normal operation.