ZR120D Hopper Feeder

The ZR120D Hopper Feeder is a heavy-duty core equipment developed by ZOOMRY specifically for high-load operations involving heavy bulk materials. As a primary 550 TPH (Tonnes Per Hour) feeder and heavy bulk material feeding equipment, it is equipped with a super-large 15 m³ capacity hopper and achieves efficient continuous feeding at a belt speed of 2.5 m/s. It features a 20 mm-thick tear-resistant reinforced belt that can withstand long-term impact and wear from heavy bulk materials, while the dual hydraulic motor drive design provides sufficient power redundancy. Combined with a fault self-diagnosis system to reduce downtime, and having obtained international certifications including CE and EAC, it has become the preferred heavy-duty feeder with "high load-bearing capacity, high reliability, and low failure rate" for heavy bulk material scenarios such as heavy mining and deep-water ports.

Core Functions of the ZR120D Hopper Feeder

As a professional heavy-duty feeder, the core competitiveness of the ZR120D Hopper Feeder lies in "heavy-load bearing + power redundancy guarantee + intelligent fault management and control". Addressing the pain points of heavy bulk materials—"large weight, strong impact, and high requirement for operational continuity"—it solves the problems of traditional feeders (such as "prone to belt tearing, insufficient power, and difficult fault diagnosis") through targeted function optimization, while meeting the dual demands of "equipment durability and operational efficiency" in heavy-load scenarios.

Reinforced Tear-Resistant Belt

The equipment's belt adopts a custom reinforced structure with a thickness of 20 mm—twice that of ordinary feeder belts. The core layer is made of high-strength polyester canvas (EP300), and the upper and lower cover rubbers are wear-resistant natural rubber (hardness: 60 Shore A). Three layers of steel mesh are transversely embedded to enhance tear resistance, resulting in a tear strength of 800 N/mm, which is 120% higher than that of ordinary belts. The belt surface is processed with diamond-shaped anti-slip patterns with a depth of 10 mm, improving the anti-slip effect by 60% for heavy bulk materials (such as large ore blocks and heavy aggregates) and preventing materials from slipping or shifting during conveying. Meanwhile, both sides of the belt are equipped with 400 mm-high wear-resistant rubber skirts with built-in steel wire skeletons, which can resist deformation caused by lateral pressure from heavy bulk materials and reduce material side leakage, adapting to the conveying needs of heavy bulk materials with "high impact and strong wear".

Dual Hydraulic Motor Drive

The drive system adopts a dual hydraulic motor linkage design, with each motor having an output power of 18 kW and a total output torque of 4500 N·m—80% higher power reserve than single-motor drives. The dual motors drive the belt drum synchronously through a planetary reducer; even if one motor fails temporarily, the other can automatically switch to the "emergency power mode", maintaining 70% of the feeding capacity (approximately 385 TPH) and avoiding full-line shutdown due to power interruption. The hydraulic system is equipped with a dual-circuit independent oil supply design, with one-way valves between the circuits to prevent the impact of oil leakage in one circuit on the overall power output. At the same time, the hydraulic oil cooling system uses forced air cooling to control the oil temperature within 40-55℃, avoiding overheating and deterioration of hydraulic oil under heavy-load operations and extending the service life of motors and hydraulic components.

Intelligent Fault Self-Diagnosis System

The equipment is equipped with a self-developed intelligent fault self-diagnosis system, which collects real-time equipment operation data through more than 20 sensors distributed in the belt, drive, and hydraulic systems (such as belt tension sensors, motor temperature sensors, and hydraulic pressure sensors). The system can automatically identify 12 types of common faults, including abnormal belt tension, hydraulic motor overheating, oil circuit leakage, and hopper blockage. When a fault is detected, the HMI touchscreen will display a fault code and troubleshooting guidelines, and an audio-visual alarm will remind the operator. The fault identification accuracy rate is over 95%. In addition, the system supports fault data storage and export (capable of storing 100 historical fault records), facilitating engineers to trace the cause of faults. The average fault diagnosis time is reduced from the traditional 2 hours to 30 minutes, significantly reducing downtime losses in heavy-load scenarios.

Core Components

The stable operation of the ZR120D Hopper Feeder in high-load heavy bulk material scenarios lies in the comprehensive upgrading of its core components around "heavy load-bearing, high wear resistance, and strong stability". From the belt to the drive, from the control system to the hopper structure, each component has undergone heavy-load condition simulation tests at ZOOMRY's Quality Testing Center to ensure long-term adaptation to the continuous operation needs of heavy bulk materials.

Dual Hydraulic Motor Drive System

The hydraulic motors are internationally renowned brand axial piston motors, with a rated working pressure of 25 MPa and a maximum speed of 1500 rpm, featuring "high torque and low noise"—the operating noise is ≤75 dB, 15% lower than that of ordinary gear motors. The motor output shaft is made of 40Cr forging material, with surface nitriding treatment (hardness ≥850 HV), improving impact resistance and wear resistance by 40% and enabling it to withstand instantaneous impact loads during heavy bulk material conveying. The supporting hydraulic power pack has an oil tank capacity of 800 L and is equipped with a triple high-precision filtration device (filtration accuracy: 5 μm), ensuring the hydraulic oil cleanliness reaches NAS Grade 7, reducing wear of hydraulic components. The annual failure rate of the system is less than 0.3%, far lower than the industry average of 1.5%, providing guarantee for the stable operation of the dual motors.

Reinforced Belt Conveying System

In addition to the 20 mm-thick tear-resistant belt, the belt conveying system has undergone multiple enhancements: the drive rollers adopt a "diamond-shaped rubber coating" design with a coating thickness of 20 mm and a friction coefficient of 0.45, ensuring sufficient friction between the belt and the rollers to prevent slipping under heavy loads; the direction-changing rollers have a chrome-plated surface (thickness: 0.1 mm), improving wear resistance by 80% and are equipped with self-aligning bearings to reduce wear caused by belt deviation; the belt tension system uses hydraulic automatic tensioning, which can adjust the tension in real time according to the belt load (tension adjustment range: 5-12 kN), avoiding belt slipping due to insufficient tension or tearing due to excessive tension. The tension response time is ≤2 seconds, adapting to scenarios with fluctuating heavy bulk material loads.

Intelligent Control System

Centered on "easy operation + intelligent diagnosis", the control system is equipped with a 12-inch high-definition color HMI touchscreen, supporting multi-language switching (including English, Russian, Spanish, etc.). The interface layout focuses on the core needs of heavy bulk material operations, retaining only key functions such as "feeding start/stop, belt speed adjustment, fault query, and motor mode switching". Ordinary operators can operate it independently after 1.5 hours of training. The system supports two control modes: local control is completed through the operation panel on the equipment itself, suitable for short-distance debugging and emergency intervention; remote control is equipped with an industrial-grade wireless remote control with a range of 80 meters, whose anti-interference performance meets the IP67 standard—even in heavy bulk material scenarios with high dust and strong vibration, the signal transmission stability remains at 99%. In emergency situations, emergency stop buttons are installed at both ends of the equipment, on the remote control, and in the central control system; pressing any of them immediately cuts off all power, ensuring the safety of heavy bulk material operations.

15 m³ Large-Capacity Hopper

The hopper adopts a "wide-mouth deep-cavity" trapezoidal structure with an effective volume of 15 m³, capable of holding two loads of a single-bucket excavator, reducing the frequency of material replenishment by feeding equipment and improving operational continuity. The inner wall of the hopper is lined with 15 mm-thick wear-resistant manganese steel plates (Mn13), whose wear resistance is 150% higher than that of ordinary carbon steel, providing significant protection against impact wear from heavy bulk materials (such as ore with a single block weight ≤500 kg). The bottom of the hopper is designed as an "inclined diversion outlet" (inclination angle: 18°), and together with the built-in arc-shaped diversion plate, it guides heavy bulk materials to flow evenly onto the belt, avoiding uneven load wear on the belt caused by local accumulation. An optional grid protection net (grid size: 300×300 mm) can be installed at the top of the hopper to prevent oversized materials from entering the hopper and causing blockage, adapting to the "uneven particle size" characteristic of heavy bulk materials.

Convenient Transportation and Efficient Installation

To address the pain points of heavy bulk material projects—"large equipment size, difficult transportation, and long installation cycle"—the ZR120D Hopper Feeder adopts a "modular disassembly + high-proportion pre-assembly" design. While ensuring heavy-load performance, it significantly reduces transportation and installation difficulties, ensuring rapid project commissioning.

Modular Transportation

The equipment is scientifically split into 4 standard modules: "hopper module, drive module, chassis module, and control system module". The size of each module strictly complies with the specifications of a 40ft high cube container (length 12.03 m × width 2.35 m × height 2.69 m): the hopper module is hydraulically folded to a height of 2.5 m and weighs less than 18 tons; the drive module and hydraulic power pack are integrated into a waterproof cabinet with dimensions of 2.2 m × 1.8 m × 2.0 m; the chassis module adopts a lightweight reinforced structure, weighing 22 tons after disassembly, eliminating the need to apply for over-width or over-weight transportation permits. Compared with the traditional "special transportation + on-site welding" mode for heavy-duty feeders, cross-border logistics costs are reduced by 45%, and core components are protected and packaged at the factory to avoid damage caused by jolts and moisture during transportation.

High Pre-Assembly Installation

Before leaving the factory, the equipment has completed 90% of pre-assembly work, including key processes such as belt installation and debugging, hydraulic pipeline connection, electrical wiring laying, and fault self-diagnosis system calibration. It has also undergone a 120-hour full-load test run (simulating a 550 TPH continuous heavy bulk material conveying scenario) to ensure no faults during on-site installation. On-site, only 3 core processes are required: first, module splicing—connecting the hopper to the chassis and the drive module to the belt frame using high-strength bolts (M30, torque: 800 N·m), which can be completed by 2 people in 1.5 hours; second, hydraulic pipeline and electrical connector docking—achieving leak-free connection using quick connectors, taking ≤1 hour; third, no-load test and parameter fine-tuning—checking belt operation, dual-motor synchronization, and fault diagnosis function. A skilled team can complete all installation and debugging and put the equipment into operation within 1 day. ZOOMRY provides a technical manual with step-by-step operation guidelines, which marks special precautions for heavy-load equipment installation (such as bolt tightening torque and hydraulic system venting steps), and also offers online technical support to help solve problems encountered during installation.

Compliance and Quality Assurance for Heavy Bulk Material Operations

International Certifications

The equipment has obtained EU CE Certification (Machinery Directive 2006/42/EC, EMC Directive 2014/30/EU) and completed 16 special tests in accordance with the safety requirements for heavy machinery, including structural load-bearing strength (simulating 5 times the rated load), emergency braking response time (≤0.5 seconds), electrical safety protection (IP65 rating verification), and electromagnetic radiation limit testing. It can directly enter the European Economic Area (EEA) market. It has also obtained EAC Certification of the Eurasian Customs Union, meeting the "low-temperature, dusty, high-load" operating environment requirements of CIS countries. Technical documents are provided in Russian, including special operation specifications and maintenance points for heavy bulk material operations, facilitating review by local regulatory authorities. In addition, the equipment fully complies with the ISO 9001 Quality Management System and ISO 14001 Environmental Management System, with a fully traceable production process—each process from raw material incoming inspection to finished product delivery has quality records, ensuring consistency in mass production.

Quality Assurance

ZOOMRY has built its own Quality Testing Center, equipped with a chemical laboratory, hardness laboratory, belt performance testing laboratory, hydraulic system high-pressure testing laboratory, and more than 60 professional testing equipment. The core components of the ZR120D Hopper Feeder undergo strict testing: the idlers adopt ZOOMRY's self-developed heavy-duty wear-resistant model, with the roller body made of 20# seamless steel pipe (wall thickness: 12 mm), radial runout ≤0.4 mm (better than China's GB standard of 0.5 mm), rotational resistance ≤2 N (better than GB standard of ≤3 N), and service life exceeding 50,000 hours; the drum shaft is made of 40Cr forging (diameter ≥159 mm), with a shell thickness of 16 mm. After CNC four-roll bending processing, the ovality is <1.5 mm; after welding, it undergoes dual testing of ultrasonic testing (UT) and magnetic particle testing (MT) to eliminate internal stress and ensure no deformation under long-term heavy bulk material load. The reinforced belt undergoes "1000 heavy block impact tests (single block weight: 500 kg)" and "500-hour wear test", and can only be installed if there is no tearing or obvious wear and its performance meets the standards. Before leaving the factory, each ZR120D undergoes 20 strict tests, including "550 TPH full-load feeding test", "dual-motor emergency switching test", "fault self-diagnosis function test", and "low-temperature startup test (-30℃)", and can only be delivered to customers after passing all tests.

Technical Parameters

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Efficiency and Cost Optimization for Heavy-Load Scenarios

By choosing the ZR120D Hopper Feeder, customers can achieve value enhancement in three key dimensions: load-bearing capacity, operational reliability, and O&M (Operation and Maintenance) costs. In terms of load-bearing capacity, the 20 mm-thick tear-resistant belt and 15 m³ hopper adapt to the "high impact and large capacity" needs of heavy bulk materials, eliminating the need for frequent belt replacement or feeding volume restriction. In terms of operational reliability, the dual hydraulic motor power redundancy avoids power interruption, and the fault self-diagnosis system shortens downtime, increasing the annual effective operating hours of the equipment to over 8000 hours. In terms of O&M costs, high-wear components (such as Mn13 hopper liners and tear-resistant belts) extend the replacement cycle, reducing O&M costs by 40% compared to ordinary feeders; the dual-motor emergency mode reduces production losses caused by shutdowns. Comprehensive calculations show that it can reduce the comprehensive cost of heavy bulk material operations by 25%.

Service Support

Based on the needs of overseas heavy bulk material projects, ZOOMRY has established a comprehensive service system integrating "technology, spare parts, and specialized training". It provides multi-language technical documents, including heavy bulk material operation manual, heavy-duty component maintenance guide, and fault diagnosis manual. The content covers professional information such as dual hydraulic motor debugging, reinforced belt replacement, and hydraulic system maintenance, accompanied by high-definition diagrams for easy customer understanding. It offers 24/7 online technical consultation with an engineer response time of no more than 3 hours—the assigned engineers all have over 8 years of experience in heavy-duty feeder services and are familiar with equipment pain points in heavy bulk material scenarios (such as belt tear repair and hydraulic motor fault diagnosis). For key spare parts such as reinforced belts, hydraulic motors, and wear-resistant liners, the delivery cycle is no more than 5 days, reducing the spare parts waiting time for heavy bulk material projects.

For key customers, ZOOMRY also provides customized services: adjusting belt pattern depth and hopper liner material according to heavy bulk material characteristics (such as particle size and hardness), and optimizing hydraulic system protection according to operating environments (such as low temperature and high salt spray). Meanwhile, it offers "specialized training for heavy bulk material operations", covering heavy-load startup skills, emergency fault handling, and daily maintenance priorities, ensuring that the customer's team fully masters the use and maintenance points of the heavy-duty feeder and guaranteeing long-term stable operation of the equipment.