BeltLineNet: A Shape-Prior-Guided Lightweight Network for Real-Time Deviation Detection in Circular Pipe Conveyors

Belt deviation in circular pipe conveyor systems could lead to material spillage, environmental contamination, reduced efficiency, and accelerated belt wear. Real-time belt deviation detection is crucial for ensuring safe and efficient operation. However, existing methods, primarily developed for flat-belt systems, heavily rely on distinct belt-background semantics, making them unsuitable for circular conveyors where indistinct target features, motion blur, and occlusions pose significant challenges. To address these issues, we reformulate the deviation detection task as an object detection problem, proposing BeltLineNet, a lightweight, real-time deviation detection network specifically designed for circular pipe conveyors. Our method integrates explicit feature learning with a coarse-to-fine global feature fusion mechanism, enhancing belt line representation under complex conditions. Additionally, a shape-prior loss strategy is introduced to improve supervision during training, ensuring more accurate detection of elongated targets. The model is also optimized for real-time deployment through layer-adaptive pruning, achieving a balance between accuracy and computational efficiency. Extensive comparative experiments involving 8 state-of-the-art (SOTA) feature extraction networks and 6 feature enhancement strategies on a self-collected dataset under industrial conditions demonstrate that BeltLineNet surpasses SOTA feature extraction and fusion networks, improving average precision (AP) by 8.23% before pruning and 6.33% after pruning.