MARKET: Mining
SAC: South America
THE PROJECT: Automatic Tensioner System
SAFETY, DURABILITY AND COST-EFFICIENCY
IMPROVING BELT CONVEYOR PERFORMANCE IN THE MINING INDUSTRY
ADDRESS: Via Prefeito Jurandyr Paixao, 1900 – Limeira – SP – Brazil - PHONE: 0055 19 3446 8600 - EMAIL: brevini.br@dana.com
The Requirement
Provide a solution to improve the performance and reliability of a counterweight belt conveyor mining application in South America. The solution needs to
- ensure correct belt tension to avoid slippage and optimize material handling performance, especially when different loads can reduce efficiency; and
- have the ability to adjust the length of the belt to compensate for stretching on different loads, facilitating transmission continuity.
our solutions
The Dana SAC serving the South American market leveraged their experience and proposed Dana’s Automatic Tensioner Systems (ATS) for belt conveyors already produced and in-use for the mining industry. The Dana SAC team replaced the existing counterweight block and tower structure with a total of 10 Dana ATS solutions, each with either a 40-ton (5) or 60-ton (5) capacity.
In addition to the new ATS solution, an automated electric winch and Dana-developed custom belt-tensioning software provided a truly customized system. With this new solution in place, correct belt tensioning was available under any running conditions.
Dana ATS features:
- software controllers developed to enable remote access via mobile app or internet browser
- Automatically balanced belt tension 100% of the time, reducing wear and avoiding premature belt rupture
- Industry-trusted Dana gearbox and winch manufacturing technologies
- Wide product range from 3- to 60-ton line pull on first layer
The Dana ATS solution ensures maximum safety during installation, operation, and maintenance, due to its ease of access. Belt lifespan is increased and compared to the counterweight block and tower structure, capital expenditure is lower for new installation, as well as ongoing operating costs.
The unique approach to this common problem yields safety, reliability, maintenance, and cost benefits that can benefit any mining site, as well as other markets moving material along a conveyor system.
key numbers
An overview of the key numbers related to the project:
10
Dana ATS - Automatic Tensioner Systems
5x
60-ton capacity units
5x
40-ton capacity units
1
Production plant - Limeira (São Paulo)
