A  solution designed to protect conveyor belts in mining and heavy aggregate operations aims to address a range of challenges, especially those encountered in loading zones, where falling materials can cause severe damage.

Tru-Trac says its EXHD dynamic impact idler bed represents a significant advancement in addressing the problems of improperly engineered loading zones that fail to distribute material evenly or align with the belt's trajectory, creating uneven wear and the increased likelihood of belt damage. The solution is designed to protect belts and enhance system reliability in demanding applications.

Tru-Trac COO Shaun Blumberg says the challenge of managing impact control in loading zones is significant for all materials handling operations: “These transfer zones are the points where materials are introduced onto the belt from chutes, often from considerable heights ranging from 2 m up to 10 m. The force of this impact can lead to various issues including belt damage, material spillage and belt misalignment. Insufficient support and impact control ultimately results in frequent maintenance needs, increased downtime and higher operational costs.”

“Traditional impact rollers, while commonly used due to their low cost, often provide inadequate shock absorption particularly in high-drop applications,” he continues. “Furthermore, poorly designed chutes and under-specified impact beds can worsen the problem.”

Specifically engineered for applications with drop heights between 2 m to 10 m, the system is designed to absorb heavy aggregate impacts safely, preventing belt damage and extending the belt's life.

The idler bed combines dynamically adjusting impact idlers with shock-absorbing springs to provide impact control. The impact idlers oscillate to adjust dynamically to the load, reducing the force transmitted to the belt. This movement allows the system to absorb and dissipate impact energy more effectively than static systems. The heavy duty springs are capable of handling loads up to 11.4 t and, working in tandem with the idlers, enhance absorption to manage high impact conditions. The design aims to minimise stress on the belt, preventing damage and enhancing durability.

Blumberg highlight’s Tru-Trac’s range of impact control solutions tailored to specific application requirements and designed to ensure that conveyor systems are protected from various types of impact forces. This includes standard impact beds, impact rollers and slider frames, which are engineered for easy installation and reduced maintenance.

The company also offers solutions to address dust and spillage around the impact or loading zone. “Proper dust and spillage control are essential for maintaining a clean and efficient conveyor environment and our solutions help to minimise material loss and prevent the accumulation of debris which can lead to additional wear and operational inefficiencies,” says Blumberg.

Inadequate impact protection can lead to increased spillage, belt misalignment and structural damage to the conveyor system, explains Blumberg. Misalignment causes the belt to drift leading to additional wear on the edges and other components which, in turn, increases maintenance requirements and potential operational downtime. Chutes that are not properly aligned with the conveyor can misdirect materials, creating irregular impact points and causing excessive localised stress on the belt. This can result in belt failure and significant operational disruptions.

“Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a significant advancement in conveyor belt protection, effectively addressing the complex challenges of impact control in loading zones and we believe that investing in high quality impact beds and ensuring proper chute design is crucial for maintaining efficient and reliable conveyor operations,” he concludes.