ESS Engineering, a leader in conveyor belt cleaning technology, has unveiled an autonomous tensioner to optimise cleaner performance.
As mining operations scale to meet global demand, conveyor systems are under increasing pressure. Faster, wider and more heavily loaded belts are now the norm, making efficient carryback control more critical than ever.
Australian mine sites present unique logistical challenges.
Many mining operations are located remotely and are largely staffed by the fly-in, fly-out (FIFO) community, which means regular site visits to inspect and maintain belt cleaners and other conveyor belt accessories are often limited to scheduled shutdowns.
Conveyor belt cleaners are essential for removing material fines from the return side of the belt. Without effective cleaning, these material fines or carryback can lead to conveyor belt mistracking, increased spillage, accelerated wear, more safety hazards, and increased potential downtime.
Maintaining correct blade-to-belt contact historically required regular adjustment by trained local technicians to control carryback.
Spring and air tensioning devices were introduced as the labour market was squeezed and site access was reduced for security and safety. This meant more time could elapse between opportunities for maintenance; however, inconsistent tensioning had resulted in uneven blade wear and reduced cleaning efficiency.
“Belt cleaner blades are designed to wear over time, but as they do the spring within the cleaner assembly extends and applies less force, causing less contact pressure with the belt,” ESS Engineering mechanical engineer Mitch Stone told Australian Mining.
During inspection and maintenance periods, trained staff recognise the issue and manually adjust the tensioning device – a reactive approach to maintenance.
The reality, as Stone said, is that “cleaners aren’t adjusted or monitored as frequently as they should be”, which frequently results in premature or uneven blade wear.
“The autonomous tensioner removes the need to adjust the belt cleaner’s blades manually, saving time and resources, especially in remote or hazardous areas,” Stone said.
ESS’ autonomous tensioner can be retrofitted to existing belt cleaner systems, connecting directly to the mainframe spring. Using intelligent control systems, the cleaner blade tension is automatically adjusted as it wears, maintaining consistent cleaning pressure and prolonging the cleaner blade’s lifespan.
How it works
The autonomous tensioner reduces much of the manual re-tensioning and monitoring with an onboard sensor and actuator package.
Sensors measure the force exerted by the cleaner arm, while a motorised mechanism automatically re-tensions the mainframe spring to restore a force predetermined through the application-specific wear rate. This closed-loop system ensures the blades wear at a consistent, linear rate, extending service life and preventing end-of-cycle acceleration that prematurely destroys blade edges.
All tension and wear data is relayed in real time via an in-built 5G antenna to a secure desktop interface.
Operators can enter wear data through a human–machine interface (HMI), inputting specific blade-wear targets into the system – for example, “typical blade life is six months” – and the tensioner will adjust the force over the life of the blade accordingly.
Adjustments can be made from a control room or any internet-connected device. In addition, a stainless-steel enclosure houses a screen that allows you to set up and adjust the autonomous tensioner at the conveyor.
Beyond safety and labour savings, the system delivers proactive maintenance intelligence.
“With the autonomous tensioner, you can monitor and operate the belt cleaner at the same time, which means you have a clear view not only of how your cleaner is wearing but also how it is performing,” Stone said.
This level of visibility helps to prevent unplanned shutdowns and optimise conveyor maintenance.
The autonomous tensioner is currently in the trial phase.
“It’s been operating for a while now at a test site, and the feedback from the client has been overwhelmingly positive,” Stone said.
As Stone attests, autonomous tensioners strongly complement ESS’ belt cleaner portfolio.
“We’re looking at this as an extension of the work we already do around operational safety,” he said. “We have a long history of providing conveyor belt cleaners – our core product – so this helps improve functions and bring our technology into the world of automation.”
This feature appeared in the October issue of Australian Mining magazine.