Broken belt Catcher

ZOOMRY Broken belt Catcher is a full-section locking core safety equipment specially designed for global bulk material conveying systems. The product is perfectly compatible with ZOOMRY's full range of main engine equipment such as Belt Conveyors, Bucket Wheel Stacker-Reclaimers, and Mobile Ship Loaders, while also adapting to mainstream international brand conveying equipment. It completely solves the pain points of traditional belt break protection such as "single adaptation, blind spots in protection, and incomplete compliance", providing global customers with a one-stop safety solution featuring "full-section locking, no-blind-spot protection, and high-reliability guarantee".

Define a New Benchmark for Full-Section Protection

In the global bulk material conveying industry, traditional broken belt catchers generally have limitations such as "narrow adaptation specifications, blind spots in protection, and single compliance standard". Especially in terms of "arrest coverage", there is a core shortcoming—they can only lock one side or part of the conveyor belt, failing to meet the development needs of modern conveying systems for "large-scale, multi-working-condition, and globalization".

ZOOMRY Broken belt Catcher is not just a simple emergency stop device for conveyor belts, but a complete belt break protection system centered on "full-section locking". It can adapt to various belt conveyors with different bandwidths, inclination angles, and belt strengths, and is compatible with ZOOMRY's own idler sets, rollers, belt cleaners and other components. It meets the compliance requirements of different regions around the world and remains stable and reliable even in extreme environments. Its core advantage lies in "synchronous full-section locking of the conveyor belt", which completely eliminates secondary risks such as belt slipping, stacking, and material falling after belt breakage, truly realizing "one piece of equipment covering all-scenario and full-dimensional protection needs".

Core Technical Features of Broken belt Catcher

Full-Section Arrest Core Structure

The equipment adopts a "symmetrical full-section clamping design", breaking through the limitations of traditional single-side arrest—at the moment of belt breakage, the symmetrically arranged wedge-shaped brake blocks synchronously tighten from both sides of the conveyor belt, locking both the load-bearing section (upper belt) and the return section (lower belt) at the same time, achieving 100% full-section coverage.

The trigger mechanism provides dual-mode adaptation: pure mechanical + gravity drive is adopted for light-load scenarios, no external power supply is required, and there is zero failure in extreme environments such as no electricity and high dust; hydraulic auxiliary trigger is added for heavy-load scenarios, with a response speed ≤0.3 seconds, ensuring instantaneous braking under large conveying capacity and high belt speed working conditions. The frame is made of Q355B high-strength section steel and alloy steel composite structure, which has passed ultrasonic flaw detection and can withstand the instantaneous impact of 1.5 times the design load. Combined with buffer braking technology, the braking deceleration is controlled at 0.2-0.5m/s², avoiding equipment damage caused by excessive arrest force.

Full-Scenario Adaptation Technology

The product adopts "modular parameter design" to achieve full-specification coverage from light load to heavy load and from small bandwidth to large bandwidth—the rated braking force ranges from 50 to 1500kN, adapting to a bandwidth of 650-2200mm, and the belt strength adaptation range is 800-4000N/mm. Whether it is a small industrial conveying line (650mm bandwidth, 50kN braking force) or a mining heavy-load belt conveyor (2200mm bandwidth, 1500kN braking force), it can be accurately matched.

At the same time, the product realizes "interface standardization" with ZOOMRY's belt conveyors, Telescopic Stackers, Truck Unloaders and other main engine equipment, and can be quickly matched without additional modification; for international brand conveying equipment, it provides "customized adaptation services" to achieve seamless compatibility by adjusting the frame size and installation interface, truly achieving "cross-brand, cross-equipment, and cross-scenario" full adaptation.

Full-Standard Compliance System

The product strictly follows the design principle of "global standard integration", fully covering domestic and foreign core standards—China's NB/T 11464-2023, EU's EN 12895, North America's ASTM D3794, international ISO 5048, etc., ensuring that technical parameters are in line with international standards.

It has also obtained multiple authoritative certifications: CE certification (essential for European market access), ATEX explosion-proof certification (for explosive environments), MA coal mine safety mark certification (exclusive for Chinese coal mine scenarios), and REACH compliance (EU chemical safety standard). Whether the customer is located in Europe, North America, Southeast Asia or China, it can directly meet the market access requirements without additional adaptation and modification, breaking global trade barriers.

Core Advantages of Broken belt Catcher

The core competitiveness of ZOOMRY Broken belt Catcher is concentrated in the differentiated value brought by "full-section locking", making it the preferred choice for global customers to replace imported products:

1. Full-section locking with no blind spots in protection: Synchronous clamping of the load-bearing section and return section completely eliminates secondary risks such as belt slipping, stacking, and material falling after belt breakage. The protection coverage rate is 100%, and the safety redundancy is far higher than that of traditional single-side arrest equipment;

2. Full-specification cross-equipment adaptation with seamless compatibility: Rated braking force 50-1500kN, bandwidth 650-2200mm, belt strength 800-4000N/mm, covering light-load, general-purpose, and heavy-load full scenarios. One product family can meet the protection needs of conveying systems of different scales and types, reducing the complexity of customer selection and the cost of spare parts storage;

3. Stable operation in all environments with reliable performance: The working temperature ranges from -40℃ to +60℃, adapting to extreme environments such as frigid cold in frigid zones, high temperature in tropical zones, coastal salt spray, and high dust in mines. The protection level is IP65-IP67 and the corrosion resistance level is C4-C5-M, ensuring long-term stable operation in humid, dusty, and corrosive environments, with a failure rate much lower than the industry average;

4. Convenient full-process operation and maintenance with controllable costs: Adopting a modular design, wearing parts (brake blocks, trigger springs) are universal with ZOOMRY's existing components such as idlers and belt cleaners, making procurement and replacement convenient; the design life is ≥10 years, and daily maintenance only requires regular appearance inspection and brake block wear detection, no complex professional tools are needed, and the long-term operation cost is 15%-25% lower than that of similar imported products.

Equipment Adaptation Matrix

Centered on "full-section locking", ZOOMRY Broken belt Catcher accurately matches the core conveying equipment of four major global industries, and collaborates with ZOOMRY's own main engines to create stable production value:

Adaptation to Core Equipment in the Mining Industry

• Underground Inclined Shaft Belt Conveyor: Adapts to a bandwidth of 1400-2200mm and an inclination angle of 15°-32°, selects the heavy-load type (800-1500kN), mechanical + hydraulic auxiliary trigger, ATEX and MA explosion-proof certifications, IP67 protection level, adapting to power-free and high-dust environments; full-section locking avoids ore falling and damaging roadway equipment, and collaborates with underground belt conveyors and scrapers to ensure 24-hour continuous operation;
• Belt Conveyor Supporting Open-Pit Mine Bucket Wheel Stacker-Reclaimer: Adapts to a bandwidth of 800-1800mm and an inclination angle of -20°~+28°, selects the general-purpose type (300-600kN), pure mechanical + gravity drive, anti-corrosion coating and wide-temperature adaptation design to resist extreme climates; full-section clamping prevents belt stacking and winding after belt breakage, and links with bucket wheel stacker-reclaimers and belt conveyors to ensure efficient production of open-pit mines.

Adaptation to Core Equipment in the Port Industry

• Belt Conveyor Supporting Mobile Ship Loader: Adapts to a bandwidth of 1400-2200mm and a belt speed of 4-6m/s, selects the heavy-load type (800-1500kN), compact frame design to adapt to installation space constraints, IP65+ protection level to resist salt spray erosion; synchronous full-section locking avoids high-speed belt slipping, collaborates with mobile ship loaders and telescopic stackers to ensure the safety of coal and ore loading without affecting ship berthing efficiency;
• Port Bulk Material Belt Conveyor: Adapts to a bandwidth of 800-1600mm and an inclination angle of -15°~+20°, selects the general-purpose type (300-600kN), quick-installation fixture design without modifying the main body of the equipment, installation can be completed within 2 hours; full-section arrest links with the port automatic control system to reduce operation interruption time and improve transfer efficiency.

Adaptation to Core Equipment in the Power Plant Industry

• Power Plant Coal-Conveying Belt Conveyor: Adapts to a bandwidth of 650-1800mm and 24-hour continuous operation, selects the general-purpose type (300-600kN), pure mechanical + gravity drive without relying on external power supply, sealed structure to prevent coal dust intrusion; full-section locking avoids boiler feed interruption caused by belt breakage, synchronously cuts off the power supply and sends a remote alarm when triggered, collaborates with coal-conveying belt conveyors and hopper feeders to ensure stable power supply;
• Power Plant Transfer Belt Conveyor: Adapts to a bandwidth of 650-1200mm and medium-low load working conditions, selects the light-load type (50-200kN), fixed/hanging dual-frame design to flexibly adapt to installation needs, easy to maintain; full-section protection provides full-process and no-blind-spot guarantee for the coal-conveying system, avoiding overall shutdown caused by local belt breakage.

Adaptation to Core Equipment in the Building Materials Industry

• Cement Plant Aggregate Belt Conveyor: Adapts to a bandwidth of 800-1800mm and conveys sand and gravel aggregates, selects the general-purpose type (300-600kN), rubber composite brake surface is wear-resistant and damage-proof, anti-corrosion coating resists cement dust erosion; full-section locking prevents aggregate spilling after belt breakage, collaborates with aggregate belt conveyors and hopper feeders to avoid production line stagnation;
• Mixing Station Fly Ash Conveying Belt Conveyor: Adapts to a bandwidth of 650-1200mm and an inclination angle of -15°~+20°, selects the light-load type (50-200kN), full-section arrest prevents fly ash leakage and environmental pollution, collaborates with fly ash conveying belt conveyors and chutes to ensure environmental compliance of building materials production.

Selection Guide for Broken belt Catcher

Selection by Core Equipment Parameters

• Light-load Type (50-200kN): Adapts to bandwidth 650-1200mm, inclination angle -15°~+20°, belt strength 800-1800N/mm, suitable for medium and low-load equipment such as small industrial conveying lines, power plant transfer belt conveyors, and light-duty belt conveyors in building materials factories;
• General-purpose Type (300-600kN): Adapts to bandwidth 800-1800mm, inclination angle -20°~+28°, belt strength 1200-3000N/mm, suitable for medium and heavy-load equipment such as power plant coal-conveying belt conveyors, port bulk material belt conveyors, and cement plant aggregate belt conveyors;
• Heavy-load Type (800-1500kN): Adapts to bandwidth 1400-2200mm, inclination angle -25°~+32°, belt strength 1800-4000N/mm, suitable for heavy-load equipment such as mining high-inclination belt conveyors and belt conveyors supporting port mobile ship loaders.

Selection by Environmental Grade

• Conventional Environment (indoor, dry, normal temperature): Select models with IP65 protection level and C4 corrosion resistance level; pure mechanical + gravity drive is preferred for light-load/general-purpose types;
• Harsh Environment (coastal salt spray, mining high dust, humidity): Select models with IP67 protection level and C5-M corrosion resistance level; mechanical + hydraulic auxiliary trigger is preferred for heavy-load types;
• Extreme Temperature (frigid zones below -40℃, tropical zones above +60℃): Select wide-temperature adaptation models; pure mechanical drive is preferred for frigid zones (to avoid hydraulic oil solidification), and heat dissipation structures can be matched for tropical zones.

Selection by Compliance Requirements

• Domestic Market (including coal mines): Requires MA coal mine safety mark certification (coal mine scenarios) and compliance with NB/T 11464-2023 standard;
• European Market: Requires CE certification, ATEX explosion-proof certification (hazardous environments), REACH compliance, and compliance with EN 12895 standard;
• North American Market: Requires compliance with ASTM D3794 standard and OSHA compliance; corresponding North American explosion-proof certification is required for explosive scenarios.

High-Quality Product Guarantee

Full-Standard Coverage

The product fully complies with domestic and foreign core standards such as China's NB/T 11464-2023, EU's EN 12895, North America's ASTM D3794, and international ISO 5048. Technical parameters and performance tests are carried out in accordance with the highest standards to ensure technical alignment with international similar products; it has obtained multiple authoritative certifications such as CE, ATEX, MA, and REACH. The certification qualifications can be queried and verified globally, providing customers with reliable compliance guarantees.

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, high and low temperature environment testing, and simulated belt breakage testing. Each product is provided with a complete test report before leaving the factory, recording key indicators such as arrest response time, braking distance, and full-section locking reliability to ensure performance meets the standards.

Full-Experience Endorsement

ZOOMRY has been deeply engaged in the bulk material conveying equipment field for many years. The engineer team has rich practical experience in global projects and is familiar with industry standards, working condition characteristics, and customer needs in different regions. 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 buffer structure optimized for full-section arrest all come from the practical precipitation of thousands of projects, demonstrating professional technical strength.

Full-Cycle Technical Support

Pre-Sales Customized Consultation

A team of senior engineers provides one-on-one selection services, formulating precise selection schemes and mechanical calculation reports based on the customer's conveying equipment parameters such as bandwidth, inclination angle, belt speed, belt strength, working environment, and compliance requirements; for special equipment (such as ultra-wide bandwidth and ultra-inclination belt conveyors), customized design services are provided, following up the entire process from structural optimization, material selection to interface adaptation to meet personalized needs.

Mid-Sales Precise Installation

Detailed installation manuals, 3D installation drawings, and video tutorials are provided to guide customers to quickly complete 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 conveying equipment and rapid put into use; real-time technical support is provided during the installation process to quickly solve various adaptation problems.

Post-Sales Intelligent Maintenance

Customer equipment files are established to regularly remind maintenance nodes and provide professional maintenance guidance suggestions; a 7×24-hour technical consultation hotline is provided to answer questions encountered by customers during operation and maintenance at any time; 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 failures caused by non-human factors during the warranty period, free repair or replacement services are provided to ensure long-term stable operation of customers.