Belt Catcher for Belt Conveyor

ZOOMRY Belt Catcher for Belt Conveyor is a core protective equipment tailor-made for various belt conveyors. Focusing on the core demand of conveyor belt break protection, it takes full-belt bidirectional arrest technology and gravity-driven structure as the core. It responds in milliseconds to sudden failures such as belt breakage and severe slipping, firmly locking the out-of-control belt, and fundamentally eliminating accidents of material falling, equipment damage, and personnel casualties. With a rated braking force ranging from 50 to 1500kN and compatibility with full-specification belt conveyor bandwidths of 650-2200mm, the product is suitable for belt conveyor systems in different industries around the world, and is an essential safety braking system for bulk material conveying in fields such as mining, ports, and power plants.

Urgent Need for Protection Against Belt Conveyor Belt Break Accidents

As the core equipment in the bulk material conveying industry, belt conveyors are widely used in key global fields such as mining, ports, power, and building materials. However, during long-term high-load operation, affected by multiple factors such as material impact, belt aging, overload operation, and excessive inclination angle, belt breakage has become an unavoidable fatal risk—especially in scenarios such as high-inclination mining belt conveyors, large port belt conveyors, and power plant coal-conveying belt conveyors, where the consequences of belt breakage accidents are extremely destructive.

For high-inclination belt conveyors in underground or open-pit mines (inclination angle 15°-32°), belt breakage may cause tens of tons of ore and coal to slide down at high speed, damaging supporting components such as idler sets, rollers, and chutes, and even triggering roadway collapse or casualties of on-site operators; if a large belt conveyor at a port bulk terminal breaks, materials such as coal and ore may fall into the ocean or terminal yards, causing environmental pollution and huge economic losses, while leading to the suspension of ship berthing operations; once a belt conveyor in a power plant's coal-conveying system breaks, it will directly cause boiler feed interruption, bringing millions of economic losses and social impacts to the enterprise.

Traditional protection schemes either rely on manual emergency response (slow response speed, unable to cope with sudden situations), adopt a single-side arrest structure (incomplete protection, prone to belt slipping), or depend on complex external power (poor reliability in extreme environments), making it difficult to meet the high safety protection requirements of modern belt conveyors. Based on practical experience from thousands of bulk material conveying projects worldwide, ZOOMRY has developed the Belt Catcher for Belt Conveyor to specifically address the pain points of traditional protective equipment, providing professional conveying equipment protection devices with "fast response, stable arrest, and wide adaptation" for various belt conveyors.

Core Technologies of Belt Catcher for Belt Conveyor

The outstanding performance of ZOOMRY Belt Catcher for Belt Conveyor stems from its deeply optimized technical architecture. From the trigger mechanism to the arrest structure, every design is developed around the actual operating conditions of belt conveyors. Verified by mechanical simulation and field tests, it ensures stability and reliability even in extreme environments.

Gravity-Driven Triggering

The product core adopts a pure mechanical + gravity-driven triggering mechanism (standard for light-load type, hydraulic auxiliary added for general-purpose and heavy-load types), without relying on external power supply, hydraulic stations, or other auxiliary equipment. It achieves automatic triggering completely through sudden changes in belt tension and gravity sensing. When the belt conveyor breaks, the belt tension drops sharply instantaneously, and the trigger mechanism unlocks quickly under the action of gravity, with a stable response time of 0.2-0.3 seconds, far exceeding the industry average.

It fundamentally avoids problems such as electromagnetic interference and power interruption. Even in extreme conditions such as power-free underground mine environments, extreme cold climates of -40℃, and high-humidity salt-spray port scenarios, it can still ensure trigger reliability. For heavy-load products, the addition of hydraulic auxiliary triggering further improves the stability of the arrest force, adapting to the needs of large belt conveyors with large conveying capacity and high belt speed, achieving "no failure in extreme environments and stable arrest in heavy-load scenarios".

Full-Belt Bidirectional Arrest

Different from the "point-contact braking" of traditional single-side arrest equipment, the Belt Catcher for Belt Conveyor adopts a symmetrical wedge-shaped brake block structure to achieve full-belt bidirectional arrest—after triggering, the brake blocks on both sides synchronously tighten towards the center of the belt, not only firmly locking the load-bearing section of the belt (to prevent material rollover and falling) but also accurately fixing the return section of the belt (to avoid belt stacking and winding around the roller). The arrest coverage rate reaches 100%, completely eliminating the protection loophole of "one-side slip".

The brake surface material is made of REACH-compliant polyurethane and rubber composite formula, which has undergone special wear-resistant treatment. The anti-slip coefficient is ≥0.8, which can effectively avoid secondary damage such as scratches and tears to the belt surface while ensuring sufficient braking friction, extending the service life of the belt conveyor's conveyor belt. At the same time, the braking deceleration is strictly controlled at 0.2-0.5m/s², and the inertial impact force is absorbed through the built-in buffer mechanism, avoiding resonance or deformation of the main structure of the belt conveyor caused by excessive braking, and balancing protection effect and equipment protection.

Easy Installation and Maintenance

The product frame is integrally formed with Q235B/Q355B high-strength section steel, and has passed ultrasonic flaw detection. The defect grade meets the JB/T4730.3 Level I standard, which can withstand the instantaneous impact force (up to 1500kN) during heavy-load arrest, ensuring structural stability under high-load working conditions. Two types of frames are available: fixed type and hanging type. The light-load type and general-purpose type support quick-installation fixture installation, without the need for fire work or drilling. A single set can be deployed within 2 hours, which can be easily adapted to existing belt conveyors without modifying the main structure.

In terms of environmental adaptation, the product's protection level reaches IP65-IP67, and the corrosion resistance level meets the ISO 12944-6 C4-C5-M standard. Key components are subjected to double treatment of galvanizing + spray coating, which can resist erosion from harsh environments such as mine dust, port salt spray, power plant coal dust, and corrosive gases in building materials factories. The working temperature ranges from -40℃ to +60℃, adapting to the operating needs of belt conveyors in different climate regions around the world such as frigid zones, tropical zones, and coastal areas.

Features of Belt Catcher for Belt Conveyor

1. Compliance with Multiple Industry Standards: The product strictly follows China's NB/T 11464-2023 "Belt Arresting Device for Belt Conveyors" industry standard, and fully complies with core international standards such as EU's EN 12895 "Safety Requirements for Bulk Material Belt Conveyors", North America's ASTM D3794 "Conveyor Belt Safety Standard", and international ISO 5048 "General Belt Conveyor Standard". It has obtained multiple authoritative certifications including CE certification, ATEX explosion-proof certification (for explosive environments), and MA coal mine safety mark certification, fully meeting the access requirements of major global markets such as Europe, North America, and Southeast Asia. No additional adaptation or modification is required for export, directly benchmarking the compliance level of international brands.

2. Strong Main Engine Coordination: As a core supporting component of ZOOMRY's bulk material conveying complete sets of equipment, the Belt Catcher for Belt Conveyor adopts a standardized size interface design with ZOOMRY's own main engine products such as belt conveyors, Telescopic Stackers, and Truck Unloaders, which can be quickly matched without additional modification, greatly improving equipment completeness and operational stability. It is also compatible with other international brand belt conveyors, with full-range parameter coverage of rated braking force 50-1500kN, bandwidth 650-2200mm, and belt strength 800-4000N/mm. Whether it is a light-load small belt conveyor, a general-purpose medium belt conveyor, or a heavy-load large belt conveyor, it can be accurately matched, realizing "one model adapts to the full series".

3. Sufficient Safety Redundancy: The product's rated braking force reserves 20%-30% safety redundancy. Verified by professional mechanical simulation, even in extreme working conditions exceeding 1.5 times the design load, it can still stably complete the arrest. The applicable inclination angle range is -25°~+32°, fully covering the belt conveyor scenarios of upward conveying, downward conveying, and horizontal conveying. The installation spacing can be dynamically adjusted according to the belt conveyor's inclination angle (10-80m for upward conveying / 30-150m for downward conveying), ensuring no protection blind spots when a belt breakage accident occurs, and providing "double insurance" for the belt conveyor system. The full-belt bidirectional arrest and buffer braking design further improve the safety and stability of protection, avoiding secondary risks caused by excessive arrest force.

4. Simple and Durable Structure: The product adopts a modular design, with core components (brake blocks, trigger mechanism, etc.) having a simple structure and low failure rate, with a design life of ≥10 years. Wearing parts are made of universal materials, sharing the supply chain with ZOOMRY's existing components such as Conveyor Rollers and Belt Cleaners. Procurement and replacement are convenient, without the need to separately reserve special spare parts. Daily maintenance only requires regular appearance inspection and brake block wear detection, without complex professional tools. Operators and maintenance personnel can complete it after simple training. The long-term operation cost is 15%-20% lower than similar imported products, achieving the dual advantages of "high reliability + low-cost operation and maintenance".

Equipment Adaptation and Application

As a core safety redundancy component of bulk material conveying equipment, ZOOMRY Belt Catcher for Belt Conveyor accurately adapts to the core conveying equipment in three major global fields: mining, ports, and power plants. It seamlessly cooperates with ZOOMRY's own main engine equipment such as belt conveyors and mobile ship loaders, building a solid safety line for the stable operation of various key equipment:

Adaptation to Core Equipment in the Mining Industry

Core conveying equipment in the mining field generally faces multiple tests of high inclination angle, heavy load, and harsh environment. The belt catcher is accurately adapted to the operating characteristics of key equipment:

• Underground Inclined Shaft Belt Conveyor: As the core equipment for underground material transfer in mines, it generally has the characteristics of 15°-32° large inclination angle and power-free/high-dust environment. The risk of belt breakage directly threatens roadway safety. ZOOMRY's heavy-load belt catcher (800-1500kN) adapts to its 1400-2200mm bandwidth requirement, adopts mechanical + hydraulic auxiliary triggering technology with a response time ≤0.3 seconds, and is equipped with ATEX and MA explosion-proof certifications and IP67 protection level. It can quickly lock the broken belt in a power-free environment, avoiding ore falling and damaging supporting components such as idler sets and chutes. It seamlessly cooperates with underground belt conveyors and scrapers to ensure 24-hour continuous operation.
• Open-Pit Mine Belt Conveyor: Long-term exposed to extreme climates, it needs to withstand temperature changes of -40~+60℃, rain and snow erosion, and the conveyed materials (iron ore, coal) have strong impact, resulting in fast belt wear. With anti-corrosion coating (ISO 12944-6 C5-M) and wide-temperature adaptation design, the belt catcher adapts to its 800-2200mm bandwidth range. The light-load/general-purpose type adopts pure mechanical + gravity drive, and the heavy-load type adds hydraulic auxiliary. The installation spacing can be dynamically adjusted according to the equipment inclination angle (10-80m for upward conveying / 30-80m for downward conveying). It cooperates with open-pit mine belt conveyors and bucket wheel stacker-reclaimers to ensure stable operation throughout the year.

Adaptation to Core Equipment in the Port Industry

Core equipment for port bulk material transfer is characterized by "large-scale and high-speed". The belt catcher provides customized adaptation schemes for equipment performance requirements:

• Belt Conveyor Supporting Mobile Ship Loader: As the key equipment for port bulk material loading, its supporting belt conveyor has the characteristics of 1400-2200mm large bandwidth and 4-6m/s high belt speed, with compact installation space and salt-spray corrosive operating environment. ZOOMRY's general-purpose/heavy-load belt catcher adopts a compact frame design to adapt to the equipment's installation space constraints. The anti-corrosion coating and IP65+ protection level can resist salt-spray erosion. The full-belt bidirectional arrest technology avoids high-speed belt stacking and winding around rollers. It is linked with mobile ship loaders and telescopic stackers, synchronously cutting off the equipment power supply when triggered, ensuring the safe transfer of coal and ore without affecting ship berthing efficiency.
• Large Port Bulk Material Belt Conveyor: Undertakes material transfer between terminal yards and loading/unloading equipment, with a bandwidth of 800-1800mm and a belt strength of 1200-3500N/mm. Belt breakage accidents are prone to cause material spilling and environmental pollution. The general-purpose belt catcher (300-600kN) adapts to its parameter requirements. The quick-installation fixture design does not require modifying the main structure of the equipment, and installation can be completed within 2 hours. It is linked with the belt conveyor's automatic control system to realize fault alarm, reducing the interruption time of terminal operations and adapting to the efficient demand of port bulk material transfer.

Adaptation to Core Equipment in the Power Plant Industry

Core equipment in power plant coal-conveying systems has core requirements of "continuity and high reliability". The belt catcher is accurately matched as a safety redundancy component:

• Power Plant Coal-Conveying Belt Conveyor: As the "lifeline" of energy supply, it needs to operate continuously for 24 hours, conveying coal and biomass fuel, with a bandwidth of 650-1800mm and an inclination angle of -15~+20°. Belt breakage will directly cause boiler feed interruption. ZOOMRY's general-purpose belt catcher (300-600kN) adapts to its parameter range. The pure mechanical + gravity-driven mode does not rely on external power supply, avoiding protection failure during power outages. The sealed structure can prevent coal dust from entering the trigger mechanism. It cooperates with coal-conveying belt conveyors and hopper feeders, and synchronously sends remote alarms when triggered, facilitating operation and maintenance personnel to quickly handle, reducing equipment downtime, and ensuring stable power supply.
• Power Plant Transfer Belt Conveyor: Connects the coal yard and the main coal-conveying line, adapting to a bandwidth of 650-1200mm and a belt strength of 800-1800N/mm, with working conditions mainly medium-low load, horizontal/small inclination angle. The light-load belt catcher (50-200kN) can flexibly adapt to equipment installation needs with dual fixed/hanging frame designs. The pure mechanical trigger structure is easy to maintain. It cooperates with transfer belt conveyors, belt cleaners and other components to provide full-process safety protection for the coal-conveying system, avoiding overall system shutdown caused by local belt breakage.

Selection Guide for Belt Catcher for Belt Conveyor

ZOOMRY Belt Catcher for Belt Conveyor provides three major series: light-load, general-purpose, and heavy-load. The core parameters cover the needs of different working conditions. Scientific selection is the key to ensuring protection effect. The following provides professional selection suggestions from three dimensions: core parameters of belt conveyors, characteristics of scenario environments, and supporting requirements, helping customers achieve "accurate adaptation and optimal cost":

Selection by Core Parameters of Belt Conveyors

• Light-load Type (rated braking force 50-200kN): Suitable for belt conveyors with bandwidth 650-1200mm and inclination angle -15°~+20°, applicable to scenarios such as small industrial conveying lines and closed belt conveyors in grain depots. The conveyed materials are grain, light building materials, etc. The pure mechanical + gravity-driven mode is preferred for low cost and easy maintenance.
• General-purpose Type (rated braking force 300-600kN): Suitable for belt conveyors with bandwidth 800-1800mm and inclination angle -20°~+28°, applicable to scenarios such as power plant coal-conveying lines and port medium-speed belt conveyors. The conveyed materials are coal, sand and gravel aggregates, etc. The mechanical + hydraulic auxiliary triggering mode balances response speed and reliability.
• Heavy-load Type (rated braking force 800-1500kN): Suitable for belt conveyors with bandwidth 1400-2200mm and inclination angle -25°~+32°, applicable to scenarios such as high-inclination mining conveying lines and port high-speed ship loaders. The conveyed materials are iron ore, heavy ore, etc. The hydraulic auxiliary triggering + fixed frame design ensures stable arrest.

Selection by Characteristics of Scenario Environments

• Explosive Scenarios (belt conveyors supporting underground coal mines and chemical workshops): Select models with ATEX or MA certification, with protection level ≥IP67, to avoid safety hazards caused by electrical components and ensure compliance with safety requirements in explosive hazardous environments.
• Corrosive Environments (ports, coastal areas, chemical parks): Select models with corrosion resistance grade C5-M. Core components are subjected to double treatment of galvanizing + spray coating to resist erosion from salt spray and corrosive gases, extending equipment service life.
• Extreme Temperature Scenarios (frigid zones, tropical zones): No additional modification is required. The product's working temperature covers -40℃~+60℃. For frigid zone scenarios, pure mechanical drive is preferred (to avoid hydraulic oil solidification), and heat dissipation structures can be matched for tropical zone scenarios to ensure reliability under different climate conditions.

Selection by Supporting Requirements

• Matching with ZOOMRY's Own Main Engine: Directly select the corresponding adapted model. Main engine products such as belt conveyors and bucket wheel stacker-reclaimers have preset installation interfaces, requiring no additional adjustments, and can quickly realize complete set deployment.
• Matching with Other Brand Main Engines: Provide parameters such as belt conveyor bandwidth, inclination angle, belt strength, and installation space. ZOOMRY's engineer team will provide customized adaptation schemes to ensure installation compatibility and protection effect.
• Remote Operation and Maintenance Requirements: Select models with intelligent diagnosis functions that can real-time monitor brake block wear and tension abnormalities, supporting remote alarm and fault diagnosis, and adapting to unattended belt conveyor systems.

Quality Assurance

International Compliance System

The product fully complies with domestic and foreign core standards such as EU's EN 12895, North America's ASTM D3794, China's NB/T 11464-2023, and international ISO 5048, ensuring that technical parameters are in line with international standards. It has obtained multiple authoritative certifications including CE certification (essential for European market access), ATEX explosion-proof certification (for explosive environments), and MA coal mine safety mark certification (access for Chinese coal mine scenarios). Among them, REACH compliance ensures that the product materials do not contain EU Substances of Very High Concern (SVHC), fully adapting to the market access rules of different regions around the world, and no additional rectification is required for export.

Full-Process Quality Control

A production control process in line with the ISO 9001 quality system has been established. Core components (frame, brake block, trigger mechanism) are made of high-quality materials, and undergo multiple inspection processes such as ultrasonic flaw detection, dynamic load testing, and high and low temperature environment testing. Before leaving the factory, the product undergoes simulated belt breakage testing. Key indicators such as arrest response time, braking distance, and locking reliability are recorded, and a complete test report can be provided to customers to ensure the performance of each product meets the standards.

Over the years, relying on stable product quality, ZOOMRY has accumulated a good reputation in the global bulk material conveying industry. The products have been verified by thousands of actual projects, with a failure rate much lower than the industry average, demonstrating reliable quality.

Professional Technical Precipitation

ZOOMRY has been deeply engaged in the bulk material conveying equipment field for many years. The engineer team has rich experience in belt conveyor system design and protection, and is familiar with industry standards and working condition characteristics in different regions around the world. Product technology iteration is based on real working condition feedback. For example, the hydraulic triggering mechanism optimized for high-inclination mining scenarios, the anti-corrosion coating upgraded for port salt spray environments, and the redundant structure designed for the continuous operation needs of power plants all come from practical experience precipitation, ensuring the practicality and advancement of product technology.

At the same time, ZOOMRY continues to pay attention to the development trend of industry technology, maintains cooperation with scientific research institutions in the global bulk material conveying industry, and constantly optimizes product design to ensure that the technical level is benchmarked against the international leading level.

Comprehensive Technical Support

ZOOMRY provides global customers with full-cycle technical support services, from selection consultation to installation and commissioning, and then to later maintenance, providing professional guarantee for customers throughout the process to ensure the product exerts the best protection effect:

Professional Selection Consultation

Relying on a team of senior engineers, it provides one-on-one selection consultation services for customers. According to the core parameters of the customer's belt conveyor such as bandwidth, inclination angle, belt speed, and conveyed materials, combined with the characteristics of the application scenario, a precise selection scheme is formulated to avoid cost waste due to over-selection or insufficient protection effect due to under-selection. At the same time, a detailed mechanical calculation report is provided to let customers clearly understand the product's protection capability and adaptability.

Installation and Commissioning Guidance

A detailed installation manual is provided to guide customers to quickly complete product installation and deployment. For large-scale projects or complex scenarios, technical engineers can be dispatched to provide on-site installation guidance and commissioning services to ensure perfect adaptation of the product to the belt conveyor system and rapid put into use. Real-time technical support is provided during the installation process to quickly solve various problems encountered by customers.

Quality Assurance and Maintenance Support

The product provides graded quality assurance services (2 years for light-load type, 3 years for general-purpose type, 5 years for heavy-load type). For product failures caused by non-human factors during the warranty period, free repair or replacement services are provided. Customer equipment files are established to regularly remind maintenance nodes, and professional maintenance guidance suggestions are provided to help customers extend equipment service life. At the same time, a 7×24-hour technical consultation hotline is provided to answer questions encountered by customers during operation and maintenance at any time.