Synchronous Winches for Conveyor Belt Systems in the Mining Industry – Precision and Safety with Modern Electric Rope Winches

Table of contents

1. Introduction
2. Electric rope winches: The Heart of Modern Conveyor Technology
3. Why Synchronous Winches Are Indispensable
4. Real-World Example: Conveyor Belt Tension in Mining
5. High tensile forces for demanding applications
6. Single-layer rope winding for maximum precision
7. Reliable operation in the case of extreme temperatures
8. Applications of Modern Winches
9. Overview of the Benefits of a Synchronous Winch
10. Custom Electric Rope Winches for Demanding Projects
11. Conclusion

In raw material extraction, reliability, precision, and maximum operational safety are among the most important factors. In the case of long conveyor belt systems, there must be even and synchronous transmission of high tensile forces. Modern electric rope winches —as synchronous winches—ensure that conveyor belts can be tensioned precisely and operated safely over the long term—even under extreme climatic conditions.

An impressive real-world example is provided by a project at the Russian apatite mine in Kirovsk (Murmansk), in the case of which several specially designed winches were used to tension the conveyor belt synchronously.

Electric rope winches: The Heart of Modern Conveyor Technology

Conveyor belts transport thousands of metric tons of material every day in mines, quarries, and industrial facilities. There must be correct tension on the conveyor belt at all times to ensure that the systems operate reliably.

Even the slightest movements can lead to:

• increased wear
• conveyor belts that are running crooked
• unplanned downtime
• high maintenance costs
• Security Risks

lead.

Here are specially designed electric rope winches are used here. They generate defined tensile forces and maintain them at a constant level over time. When two tension points are moved simultaneously, this is referred to as a synchronous winch.

Why Synchronous Winches Are Indispensable

In the case of large conveyor systems, it is not enough to tension just one side of a conveyor belt. There must be tension applied at several points in perfect synchronization.

Even a difference of just a few millimeters between both ropes can:

• affect the ribbon’s movement,
• Apply more load to the rollers,
• Damage bearings,
• Reduce the flow rate.

That is why modern synchronized winches are electronically controlled and precisely coordinated with one another.

The system used in the reference project tensioned various conveyor belts simultaneously at two points and kept them in constant synchronization.

Real-World Example: Conveyor Belt Tension in Mining

PLANETA developed several high-performance electric rope winches for a conveyor belt system at the apatite mine in Kirovsk (Murmansk, Russia).

Project Overview

• Location: Kirovsk, Murmansk (Russia)
• Application: Conveyor belt tensioning
• Completed: 2016
• Application: Synchronous tensioning of various conveyor belts at two points

Several electric rope winches from the following series:

• PHW-E 310
• PHW-E 311

with engine power ranging from

• 11.0 kW.
• 5.5 kW
• 7.5 kW

High tensile forces for demanding applications

In mining, enormous forces act on conveyor systems.

The winches used generate pulling forces of:

• up to 39 kN
• up to 54 kN
• up to 55 kN

in the case of a rope speed of 4 m/min. At the same time, rope lengths of up to 73 meters are safely accommodated.

This combination enables extremely precise and uniform conveyor belt tension—even in the case of large systems.

Single-layer rope winding for maximum precision

One particular challenge was that both ropes must run in perfect sync.

For this reason, the electric rope winch was designed with a single-layer rope winding.

This construction method offers important benefits:

• Constant cable geometry
• uniform spooling
• precise positioning
• identical rope speed
• utmost synchrony

The disadvantage of a single-layer spooling is the larger drum diameter, because there must be a single layer to store the entire length of the rope. Nevertheless, this solution is technically the best choice for high-precision synchronous applications.

Reliable operation in the case of extreme temperatures

Mines often work under the most challenging climatic conditions.

In the Murmansk project, the synchronized winches must have reliably withstood temperatures as low as –40 °C.

To this end, a monitored open drum brake with a protective cover was integrated between the transmission and the engine.

This design ensures:

• reliable braking performance
• high operational reliability
• Protection Against Icing
• Reliable operation even in Arctic climates.

Applications of Modern Winches

High-Performance electric rope winches and synchronous winches are used today in applications far beyond the mining industry.

Typical applications include:

• Conveyor Systems
• Open-pit mining
• Underground Mining
• Bulk Material Handling Technology
• Port facilities
• Steel mills
• Cement plants
• Recycling facilities
• Mechanical Engineering
• Plant Engineering

Whenever loads must be moved in sync or tensioned with precision, specially designed tension winches provide maximum process reliability.

Overview of the Benefits of a Synchronous Winch

A modern synchronous winch offers numerous technical benefits:

• Precise synchronization of more ropes
• even load distribution
• reduced wear
• longer service life of the conveyor system
• high positioning accuracy
• reliable continuous operation
• Reliable clamping force control
• Customization to meet customer requirements

Particularly in continuous industrial operation, these characteristics lead to higher system availability and lower maintenance costs.

Custom Electric Rope Winches for Demanding Projects

Standard solutions quickly reach their limits in the case of complex conveyor systems.

That is why many electric rope winches are designed specifically for their respective applications.

Possible adjustments include:

• Custom drum diameters
• Special Gearbox
• special control systems
• Synchronous Controllers
• different cable capacities
• Special Braking Systems
• Temperature Variants
• customer-specific security features

This results in tension forces that are precisely tailored to the requirements of each project.

Conclusion

Whether in mining, plant engineering, or heavy industry—modern electric rope winches do far more than simply pull loads. As precise synchronous winches, they ensure the exact tension and positioning of conveyor systems, increase operational safety, and minimize wear.

The project at the apatite mine impressively demonstrates how well-engineered design, single-layer rope winding, and precise synchronous control enable reliable continuous operation even under extreme conditions. For companies in the mining, industrial, and mechanical and plant engineering sectors, custom-designed winches are so essential to efficient and durable material-handling systems.