ZOOMRY
ZOOMRY Belt Catcher for belt conveyor focuses on precise protection against sudden failures such as belt breakage and severe slipping. Integrating dual-trigger technology of gravity drive and hydraulic assistance, it achieves millisecond-level response and full-belt bidirectional locking. With a rated braking force range of 50-1500kN, it is compatible with full-specification belt widths of 650-2200mm and covers all inclination angle operating scenarios of -25~+32°. It not only eliminates accidents such as material falling, equipment damage and personal injury, but also avoids secondary damage to the belt. As an essential safety redundancy equipment for bulk material conveying systems in mining, port, power plant, building materials and other industries, it fully complies with core international safety standards.
Core Product Parameters Table
| Parameter Name | Light-Load Type | General-Purpose Type | Heavy-Load Type |
|---|---|---|---|
| Rated Braking Force (kN) | 50-200 | 300-600 | 800-1500 |
| Applicable Belt Width (mm) | 650-1200 | 800-1800 | 1400-2200 |
| Belt Strength Adaptation Range (N/mm) | 800-1800 | 1200-3000 | 1800-4000 |
| Capture Method | Full-Belt Bidirectional Capture | Full-Belt Bidirectional Capture | Full-Belt Bidirectional Capture |
| Trigger Mode | Pure Mechanical + Gravity Drive | Mechanical + Hydraulic Assistance | Mechanical + Hydraulic Assistance |
| Applicable Inclination Angle (°) | -15~+20 | -20~+28 | -25~+32 |
| Braking Deceleration (m/s²) | 0.2-0.3 | 0.2-0.4 | 0.3-0.5 |
| Installation Spacing (Upward/Downward Conveying) (m) | 30-80/80-150 | 20-60/50-120 | 10-30/30-80 |
| Frame Type | Fixed/Suspended | Fixed/Suspended | Fixed |
| Operating Temperature (℃) | -40~+60 | -40~+60 | -40~+60 |
Core Advantages of Belt Catcher for Belt Conveyor
Strong Host Compatibility
It is compatible with ZOOMRY's own host equipment such as belt conveyors and stacker-reclaimers. With standardized size and interface design, it can be quickly matched without additional modification. Meanwhile, it adapts to various domestic and foreign brand belt conveyors—whether light-load small machines, general-purpose medium machines or heavy-load large machines, all can be accurately matched through the coverage of 50-1500kN graded braking force and 650-2200mm wide belt width. There is no need to distinguish the operation direction of the conveyor; it is universally applicable for upward, downward and horizontal conveying. The installation spacing can be dynamically adjusted according to the inclination angle (10-80m for upward conveying / 30-150m for downward conveying) to ensure no protection blind spots.
More Reliable Protection
The rated braking force reserves 20%-30% safety redundancy. Verified by professional mechanical simulation, it can still stably complete capture and locking even under extreme working conditions exceeding 1.5 times the design load. The full-belt bidirectional capture technology achieves 100% coverage—it not only locks the carrying section of the belt to prevent material rollover and falling, but also fixes the return section of the belt to avoid stacking and winding around the drum, completely eliminating the loophole of "one-sided slip". 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 to avoid resonance or deformation of the main structure of the belt conveyor due to excessive braking force.
High Structural Durability
The frame is integrally formed with Q235B/Q355B high-strength section steel, inspected by ultrasonic flaw detection, with a defect grade meeting JB/T4730.3 Level I standard, capable of withstanding the instantaneous impact force during heavy-load capture (up to 1500kN). The product has a protection level of IP65-IP67 and a corrosion resistance level in line with ISO 12944-6 C4-C5-M standard. Key components undergo double treatment of galvanizing + spray coating, able to resist erosion from harsh environments such as high dust in mines, salt spray in ports, coal dust in power plants, and corrosive gases in building materials factories. The design life is no less than 10 years, and the failure rate is much lower than the industry average.
Low-Cost Long-Term Operation and Maintenance
Core components adopt a modular design. Wear parts such as brake blocks and trigger springs share the supply chain with ZOOMRY's existing components such as idlers and cleaning scrapers, featuring strong versatility. Customers can quickly purchase and replace them without separately storing special spare parts. Daily maintenance only requires regular visual inspection and brake block wear detection, no complex professional tools are needed. Operation and maintenance personnel can complete the operation after simple training, and the long-term operating cost is significantly lower than that of similar imported products.
Key Technical Highlights
Dual-Mode Intelligent Trigger System
The light-load type is equipped with a standard pure mechanical + gravity drive trigger mechanism, requiring no external power supply, hydraulic station or other auxiliary equipment. It realizes automatic triggering completely through sudden changes in belt tension and gravity sensing. This fundamentally avoids problems such as electromagnetic interference and power interruption. Even in extreme conditions such as powerless environments in underground mines, -40℃ extremely cold climates, and high-humidity salt spray scenarios in ports, the response time can still be stably within 0.3 seconds, ensuring that protection does not fail.
On this basis, the general-purpose and heavy-load types add hydraulic auxiliary triggering technology, combined with high-precision tension sensors and speed monitoring modules, which can capture abnormal signals such as sudden drop in belt tension and overspeed slipping in real time, and automatically complete the full process of "monitoring-judgment-triggering". The response speed is further increased to 0.2-0.3 seconds. The hydraulic system adopts an explosion-proof design, adapting to high-throughput and high-belt-speed heavy-load scenarios. The braking force can be automatically adjusted according to the load, balancing capture stability and belt protection.
Full-Belt Bidirectional Locking Technology
It adopts a symmetrical wedge-shaped brake block structure. After triggering, the brake blocks on both sides synchronously tighten towards the center of the belt to achieve uniform force locking across the entire belt surface. The brake block material is a REACH-compliant polyurethane and rubber composite formula, subjected to special wear-resistant treatment, with a slip resistance coefficient ≥0.8. While ensuring sufficient braking friction, it can effectively avoid secondary damage such as scratches and tears to the belt surface, extending the service life of the Conveyor Belt.
Different from the "point contact braking" of traditional single-side capture equipment, this design does not require distinguishing the operation direction of the conveyor. One device can meet the protection needs of multiple directions such as upward, downward and horizontal conveying, greatly reducing the equipment procurement and installation costs of enterprises. After the accident is handled, the capture mechanism can be quickly reset, helping the production line resume operation quickly and reducing downtime.
Convenient Installation Design
According to the needs of different scenarios, two frame types are provided: fixed and suspended (the heavy-load type is fixed). Light-load and general-purpose types support quick-installation fixture mounting, no welding or drilling is required, and a single set of equipment can be deployed in only 2 hours. Even for existing belt conveyors, it can be easily adapted without modifying the main structure, greatly reducing transformation and installation costs.
The heavy-load type adopts bolt fixing + foundation reinforcement design to ensure installation stability in high-inclination and high-throughput scenarios, coping with the instantaneous impact force of heavy-load working conditions such as high-inclination conveyor lines in mines and belt conveyors supporting large ship loaders in ports. The frame structure has undergone strict stress testing, able to withstand the mechanical impact caused by long-term heavy-load capture, ensuring stable and durable structure.
Industry Applicable Scenarios
Mining Industry
Underground inclined shaft belt conveyors and open-pit mine belt conveyors in the mining field generally face complex working conditions such as 15°-32° large inclination angles, heavy-load material impact, high dust, and humidity without electricity. The belts wear quickly and the risk of belt breakage is extremely high. ZOOMRY's heavy-load Belt Catcher for Belt Conveyor adapts to the demand for large belt widths of 1400-2200mm. The mechanical + hydraulic auxiliary triggering technology ensures quick locking at the moment of belt breakage, avoiding tens of tons of ore and coal sliding down at high speed to damage supporting components such as idler groups and chutes, or causing safety accidents such as roadway collapse.
Meeting the explosion-proof requirements of underground coal mines, the product has passed ATEX and MA Coal Mine Safety Mark certifications, with a protection level of IP67, able to effectively resist erosion from high dust and humid environments. It seamlessly collaborates with equipment such as underground coal mine belt conveyors and scraper feeders, ensuring 24-hour continuous operation, reducing accident downtime losses, and building a solid line of defense for safe production in mines.
Port Industry
Mobile Ship Loader supporting belt conveyors and large bulk material belt conveyors at port bulk terminals are characterized by large belt widths of 1400-2200mm and high belt speeds of 4-6m/s. They are also exposed to the high salt spray and high humidity maritime climate for a long time. Belt breakage accidents are likely to cause materials to spill into the ocean or yards, environmental pollution and operation interruption. ZOOMRY's general-purpose and heavy-load belt catchers adopt anti-corrosion coatings and IP65+ protection levels to resist salt spray erosion; the full-belt bidirectional capture technology avoids stacking and winding of high-speed running belts around the drum, preventing further equipment damage.
The equipment links with the port automatic control system, synchronously cutting off the power supply of the belt conveyor and issuing a fault alarm when triggered, facilitating quick handling by operation and maintenance personnel. The quick-installation design of light-load and general-purpose types does not require modifying the structure of existing equipment, adapting to the transformation needs of existing port belt conveyors, ensuring the safe transfer of bulk materials such as coal and ore, and not affecting ship berthing efficiency.
Power Plant Industry
Belt conveyors in the coal conveying systems of power plants need to operate continuously for 24 hours, transporting materials such as coal and biomass fuel. Belt breakage accidents will directly lead to boiler fuel cut-off and power generation interruption. ZOOMRY's general-purpose Belt Catcher for Belt Conveyor (300-600kN) is suitable for medium and low inclination angle (-15~+20°) working conditions in power plants. The pure mechanical + gravity drive mode does not rely on external power supply, avoiding the risk of protection failure during power outages.
The product adopts a sealed structure design, which can effectively prevent coal dust from entering the trigger mechanism, ensuring stable operation of the equipment in high-dust environments. It works in collaboration with equipment such as power plant coal conveying belt conveyors and hopper feeders. When triggered, it synchronously sends remote alarm signals, facilitating operation and maintenance personnel to quickly locate and handle faults, reducing downtime and ensuring stable power supply. For medium and low-load scenarios such as power plant transfer belt conveyors, the light-load product (50-200kN) has become an ideal choice for full-process protection of coal conveying systems due to its flexible installation method and simple maintenance characteristics.
How to Select Belt Catcher for Belt Conveyor
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Select by core parameters of the belt conveyor: Clarify the belt width, inclination angle, belt strength of the belt conveyor and the weight per unit length of the conveyed material, and determine the required minimum braking force through mechanical calculation. For light-load working conditions (such as small-scale industry, grain depots), the 50-200kN series can be selected; for medium-load working conditions (such as power plant coal conveying, port medium speed), the 300-600kN series can be selected; for heavy-load working conditions (such as mining high inclination angle, port high speed), the 800-1500kN series can be selected. Ensure that the selection not only meets the protection needs but also avoids cost waste.
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Select by environmental working conditions: For explosion-proof scenarios (such as underground coal mines, belt conveyors supporting chemical workshops), select models with ATEX or MA certification, with a protection level ≥IP67; for corrosive environments (such as ports, coastal areas, chemical parks), select models with corrosion resistance level C5-M, and core components undergo double anti-corrosion treatment; for frigid zone scenarios, prioritize light-load models with pure mechanical drive to avoid hydraulic oil solidification affecting performance; for tropical zone scenarios, heat dissipation structures can be matched to ensure stable operation of the equipment in high-temperature environments.
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Select by supporting and operation & maintenance needs: If matching ZOOMRY's own hosts (belt conveyors, stacker-reclaimers, etc.), the corresponding adapted models can be directly selected without additional adjustments; if adapting to other brand hosts, parameters such as belt conveyor frame size, installation space, belt width and belt strength need to be provided, and engineers will offer customized adaptation plans. For remote unattended scenarios, models with intelligent diagnosis function can be selected, supporting real-time monitoring of brake block wear, tension abnormalities and other states, realizing remote alarm and fault diagnosis.
ZOOMRY Quality Assurance and Service Support
International Compliance System
The product strictly follows China's industry standard NB/T 11464-2023 "Belt Arrestors for Belt Conveyors", and also fully complies with core international standards such as EU EN 12895 "Safety Requirements for Bulk Material Belt Conveyors", North American ASTM D3794 "Conveyor Belt Safety Standard", and international ISO 5048 "General Purpose Belt Conveyor Standard". It has obtained multiple authoritative certifications including CE Certification (essential for European market access), ATEX Explosion-Proof Certification (applicable to explosive environments), and MA Coal Mine Safety Mark Certification. Among them, REACH compliance ensures that the product materials do not contain EU Substances of Very High Concern (SVHC), fully meeting the access requirements of major global markets without the need for additional adaptation and modification 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 all made of high-quality materials. Raw materials must undergo strict material inspection and performance testing before procurement to ensure they meet design requirements. Advanced processes such as CNC machining centers and automated welding equipment are adopted in the production process. Key processes implement full-process quality traceability. Each piece of equipment must undergo multiple rounds of inspections including static testing, dynamic simulation testing and extreme working condition testing. Before leaving the factory, the product will undergo a simulated belt breakage test. Key indicators such as capture response time, braking distance and locking reliability are recorded, and a complete test report can be provided to customers to ensure that each product meets performance standards.
Professional Technical Support
A team of senior engineers provides one-on-one selection consulting services. Based on the core parameters of the customer's belt conveyor such as belt width, inclination angle, belt speed and conveyed materials, combined with the characteristics of the application scenario, a precise selection plan is formulated, and a detailed mechanical calculation report is provided, allowing customers to clearly understand the product's protection capability and adaptability.
For large-scale projects or complex scenarios, technical engineers can be dispatched to provide on-site installation guidance, commissioning and acceptance services to assist customers in quickly completing equipment installation and system adaptation. At the same time, technical training on equipment operation, maintenance and fault diagnosis is provided to customers to ensure that operators and maintenance personnel are proficient in relevant skills.
A 7×24 global technical consultation hotline has been established. Whether customers are located domestically or overseas, they can obtain troubleshooting, technical guidance and other services at any time. The product provides graded warranty services (2 years for light-load models, 3 years for general-purpose models, 5 years for heavy-load models). For product failures caused by non-human factors during the warranty period, free repair or replacement services are provided; after the warranty period, lifelong maintenance services are offered, with reasonable component costs charged. Customer equipment files are established, and maintenance nodes are regularly reminded to ensure long-term stable operation of the equipment.
