Digital twins and visual monitoring of conveyor systems require accurate digital models of dynamic bulk material flows, but existing methods struggle to achieve both speed and precision. This study develops a rapid online method to reconstruct dynamic bulk material flows on conveyor belts. First, a standardized online reconstruction scheme using visual detection of material flow contour lines is presented. Then, a feature detection algorithm is proposed to extract more refined points from laser line skeleton to accelerate the reconstruction process. An iterative-filtering interpolation algorithm that generates smooth interframe point clouds is introduced to improve mesh quality. Experimental results demonstrate that our method outperforms traditional corner detection-based reconstruction techniques in feature point detection, accuracy, mesh quality, and runtime performance. This research provides a practical solution for material handling digitalization, promoting the advancement of conveyor system digital twins and potentially improving operational efficiency and predictive maintenance in bulk material handling industries.

As an important part of modern coal mine production, conveyor belts are widely used in the coal collection and transportation. In order to ensure the safe operation of the coal mine conveyor belt and solve the drawbacks of the existing conveyor belt longitudinal tear detection technology, a multispectral visual detection method for conveyor belt longitudinal tear is proposed in this paper. The experimental results show that the multispectral visual detection method not only can identify the conveyor belt longitudinal tear, but also accurately classifies and identify other states of the conveyor belt. The accuracy of multispectral visual detection method is over 90.06%, and the precision of longitudinal tearing recognition is over 92.04%. The proposed method is verified to meet the requirements of reliability and real-time in the industrial field.