Industrial Winch

Conveyor Take-Up Winch

WHERE THEY ARE USED: The Conveyor Constant Tension Winch is used extensively around the world in underground mines, underground tunnelling, and overland belt conveyors. The belt conveyors can be up to several thousand feet long and transport bulk material like coal, ore and soda.

HOW THEY WORK: The Conveyor Constant Tension Winch is used to prevent sagging between carrier idlers during startup, continuous operation, and stopping by moving an idler pulley on the slack side of the belt. The winch drive motor is controlled by an AC flux vector drive to maintain the proper belt tension. The brake is released during normal operation, but is engaged when the conveyor is stopped or during the critical event of an emergency stop. The spooling device ensures the wire rope sling is neatly arranged across the drum and automatically guided the layering of wire rope. The tension arm helps the wire sling to stay tightly wound across the drum. There are limit switch provide on upper size model to detect the end of wire rope and when the drum is full. Standalone control panel is provided for operation both manually or remotely from DCS or PLC. Soft Start and Soft Stop features are also available in control system. Minimum man-power required to operate this massive system.

PROBLEMS SOLVED: Dry friction brakes are affected by the dust, dirt, water, oil, and other substances inherent to the underground and outdoor environments making them very susceptible to failure. The large coil of a dry friction brake is slow to respond. During an emergency stop these problems can cause the winch to go into a dangerous overspeed condition which can damage the winch, brake friction pads, and idler carriage. If this happens the idler no longer provides tension to the conveyor belt and the conveyor drive or backstop can’t stop the load which then is dumped at the end of the conveyor. The force control brake provides smooth, reliable and quick braking under all conditions to stop the winch without losing tension in the conveyor belt during an emergency stop.

PRIME MOVER: Our every model is drive with Planetary Gearbox coupled with electric motor or hydraulic motor as per client choice. Planetary gearbox offer several advantages over other types of gearboxes, including higher power density, compact size, and light weight.

The power density of planetary gearboxes is high because the load is shared by multiple planet gears, which allows for more efficient energy transfer. This, coupled with the fact that driving and driven members are concentric, make planetary gearboxes more compact and space-saving than other types of gearboxes.

Planetary gearboxes also have a high torque transmitting capacity due to the distribution of the load across several planets, making them stable and long-lasting. They are also highly efficient, with low power losses and transmission efficiency up to 98% for the first stage of the gearbox. Overall, planetary gearboxes offer a range of advantages that make them suitable for various industrial applications, including those that require high gear ratios in compact spaces.

Coupled with electrical Stall Torque Motor, which make this type of winch the best performing system that is unbeatable and fail-safe. Stall Torque Motor is a special designed asynchronous motor. Its operating principle is the same as induction motor, but the required speed and mechanical properties are obtained by increasing the rotor resistance. Compared with the same rank induction motor, the torque motor has a larger stall torque and the characteristic of stable operation at low speeds, so it is suitable for tension control applications of high loading and low speeds, or for operations in which a stop position is reached after a short-time running and has to be maintained safely. They are designed to be able to control their torque and can be stalled (the motor speed is zero) continuously without overheating, which are significant characteristics of the motors that are used in tension control.